Multi-Stage Process for Producing a Material of a Battery Cell

Abstract

A system and method thereof are provided for multi-stage processing of one or more precursor compounds into a battery material. The system includes a mist generator, a drying chamber, one or more gas-solid separators, and one or more in-line reaction modules comprised of one or more gas-solid feeders, one or more gas-solid separators, and one or more reactors. Various gas-solid mixtures are formed within the internal plenums of the drying chamber, the gas-solid feeders, and the reactors. In addition, heated air or gas is served as the energy source within the processing system and as the gas source for forming the gas-solid mixtures to facilitate reaction rate and uniformity of the reactions therein. Precursor compounds are continuously delivered into the processing system and processed in-line through the internal plenums of the drying chamber and the reaction modules into final reaction particles useful as a battery material.

1 . A material of a battery cell, comprising:
 one or more final reacted solid particles of a reaction product obtained from a process comprising:
 forming a mixture from a mist of a liquid mixture and a flow of a first gas and drying the mixture at a drying temperature to form into a first gas-solid mixture; 
 separating the first gas-solid mixture into a first type of solid particles and a first side product and delivering the first type of solid particles into a reactor; 
 forming a second gas-solid mixture inside the reactor from the second type of solid particles and a flow of a second gas that is heated to a reaction temperature; 
 reacting the second gas-solid mixture inside the reactor and forming the one or more final reacted solid particles of the reaction product. 
   
     
     
         2 . The method of  claim 1 , wherein the drying temperature is lower than the reaction temperature. 
     
     
         3 . The material of  claim 1 , wherein the first gas comprises a gas selected from the group consisting of air, oxygen, carbon dioxide, nitrogen gas, inert gas, noble gas, and combinations thereof and is heated to a temperature of between 70° C. and 600° C. 
     
     
         4 . The material of  claim 1 , wherein the second gas comprise a gas selected from the group consisting of air, oxygen, carbon dioxide, an oxidizing gas, nitrogen gas, inert gas, noble gas, and combinations thereof and is heated to a temperature of between 400° C. and 1300° C. 
     
     
         5 . The material of  claim 1 , wherein the liquid mixture is selected from the group consisting of a solution of two or more metal-containing precursors, a slurry of metal-containing precursors, a gel mixture of metal-containing precursors, and combinations thereof. 
     
     
         6 . The material of  claim 5 , wherein the metal-containing precursors comprises a metal-containing compound selected from the group consisting of metal salts, lithium-containing compound, cobalt-containing compound, manganese-containing compound, nickel-containing compound, lithium sulfate (Li 2 SO 4 ), lithium nitrate (LiNO 3 ), lithium carbonate (Li 2 CO 3 ), lithium acetate (LiCH 2 COO), lithium hydroxide (LiOH), lithium formate (LiCHO 2 ), lithium chloride (LiCl), cobalt sulfate (CoSO 4 ), cobalt nitrate (Co(NO 3 ) 2 ), cobalt carbonate (CoCO 3 ), cobalt acetate (Co(CH 2 COO) 2 ), cobalt hydroxide (Co(OH) 2 ), cobalt formate (Co(CHO 2 ) 2 ), cobalt chloride (CoCl 2 ), manganese sulfate (MnSO 4 ), manganese nitrate (Mn(NO 3 ) 2 ), manganese carbonate (MnCO 3 ), manganese acetate (Mn(CH 2 COO) 2 ), manganese hydroxide (Mn(OH) 2 ), manganese formate (Mn(CHO 2 ) 2 ), manganese chloride (MnCl 2 ), nickel sulfate (NiSO 4 ), nickel nitrate (Ni(NO 3 ) 2 ), nickel carbonate (NiCO 3 ), nickel acetate (Ni(CH 2 COO) 2 ), nickel hydroxide (Ni(OH) 2 ), nickel formate (Ni(CHO 2 ) 2 ), nickel chloride (NiCl 2 ), aluminum (AD-containing compound, titanium (Ti)-containing compound, sodium (Na)-containing compound, potassium (K)-containing compound, rubidium (Rb)-containing compound, vanadium (V)-containing compound, cesium (Cs)-containing compound, chromium (Cr)-containing compound, copper (Cu)-containing compound, magnesium (Mg)-containing compound, iron (Fe)-containing compound, and combinations thereof. 
     
     
         7 . The material of  claim 1 , wherein the one or more final reacted solid particles comprise an oxide compound with two or more metals comprising lithium (Li), and a metal selected from the group consisting of cobalt (Co), manganese (Mn), nickel (Ni), aluminum (Al), magnesium (Mg), titanium (Ti), sodium (Na), potassium (K), rubidium (Rb), vanadium (V), cesium (Cs), chromium (Cr), copper (Cu), iron (Fe), and combinations thereof. 
     
     
         8 . The material of  claim 1 , wherein the one or more final reacted solid particles comprise a material selected from the group consisting of a metal oxide, titanium oxide, chromium oxide, tin oxide, copper oxide, aluminum oxide, manganese oxide, iron oxide, a metal oxide with two or more metals, lithium transitional metal oxides, lithium titanium oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel oxide, lithium iron phosphate, lithium cobalt phosphate, lithium manganese phosphate, lithium nickel phosphate, sodium iron oxide, sodium iron phosphate, a metal oxide with three or four intercalated metals, lithium nickel cobalt oxide, lithium nickel manganese oxide, lithium nickel manganese cobalt oxide, Li a Ni b Mn c Co d O e  in layered structures, Li a Ni b Mn c Co d O e  in layered-layered structures, LiNi x Mn y Co z O 2  (where x+y+z=1), LiNi 0.33 Mn 0.33 Co 0.33 O 2 , LiNi 0.6 Mn 0.2 CO 0.2 O 2 , LiNi 0.5 Mn 0.3 Co 0.2 O 2 , LiNi 0.7 Mn 0.4 Co 0.2 O 2 , LiNi 0.7 Mn 0.5 Co 0.15 O 2 , LiNi 0.8 Mn 0.1 Co 0.1 O 2 , a mixed metal oxide with doped metal, Li a (Ni x Mn y Co z )MeO b  (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), Li a (Ni x Mn y Co z )MeO b F c (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), lithium cobalt aluminum oxide, lithium nickel cobalt aluminum oxide, sodium iron manganese oxide, and combinations thereof. 
     
     
         9 . The material of  claim 1 , wherein the first gas-solid mixture is separated into the first type of solid particles using one or more separators selected from the group consisting of cyclones, electrostatic separators, electrostatic precipitators, gravity separators, inertia separators, membrane separators, fluidized beds, classifiers, electric sieves, impactors, particles collectors, leaching separators, elutriators, air classifiers, leaching classifiers, and combination thereof. 
     
     
         10 . A material of a battery cell, comprising:
 one or more final reacted solid particles of a reaction product obtained from a process comprising:   forming a mixture from a mist of a liquid mixture and a flow of a first gas and drying the mixture at a drying temperature to form into a first gas-solid mixture;   separating the first gas-solid mixture into a first type of solid particles and a first side product;   forming a second gas-solid mixture from the first type of solid particles and a flow of a heated gas;   separating the second gas-solid mixture into a second type of solid particles and a second side product and delivering the second type of solid particles into a reactor;   forming a third gas-solid mixture inside the reactor from the second type of solid particles and a flow of a third gas that is heated to a reaction temperature; and   reacting the third gas-solid mixture inside the reactor and forming the one or more final reacted solid particles of the reaction product.   
     
     
         11 . The material of  claim 10 , wherein the liquid mixture is selected from the group consisting of a solution of two or more metal-containing precursors, a slurry of metal-containing precursors, a gel mixture of metal-containing precursors, and combinations thereof. 
     
     
         12 . The material of  claim 11 , wherein the metal-containing precursors comprises a metal-containing compound selected from the group consisting of metal salts, lithium-containing compound, cobalt-containing compound, manganese-containing compound, nickel-containing compound, lithium sulfate (Li 2 SO 4 ), lithium nitrate (LiNO 3 ), lithium carbonate (Li 2 CO 3 ), lithium acetate (LiCH 2 COO), lithium hydroxide (LiOH), lithium formate (LiCHO 2 ), lithium chloride (LiCl), cobalt sulfate (CoSO 4 ), cobalt nitrate (Co(NO 3 ) 2 ), cobalt carbonate (CoCO 3 ), cobalt acetate (Co(CH 2 COO) 2 ), cobalt hydroxide (Co(OH) 2 ), cobalt formate (Co(CHO 2 ) 2 ), cobalt chloride (CoCl 2 ), manganese sulfate (MnSO 4 ), manganese nitrate (Mn(NO 3 ) 2 ), manganese carbonate (MnCO 3 ), manganese acetate (Mn(CH 2 COO) 2 ), manganese hydroxide (Mn(OH) 2 ), manganese formate (Mn(CHO 2 ) 2 ), manganese chloride (MnCl 2 ), nickel sulfate (NiSO 4 ), nickel nitrate (Ni(NO 3 ) 2 ), nickel carbonate (NiCO 3 ), nickel acetate (Ni(CH 2 COO) 2 ), nickel hydroxide (Ni(OH) 2 ), nickel formate (Ni(CHO 2 ) 2 ), nickel chloride (NiCl 2 ), aluminum (AD-containing compound, titanium (Ti)-containing compound, sodium (Na)-containing compound, potassium (K)-containing compound, rubidium (Rb)-containing compound, vanadium (V)-containing compound, cesium (Cs)-containing compound, chromium (Cr)-containing compound, copper (Cu)-containing compound, magnesium (Mg)-containing compound, iron (Fe)-containing compound, and combinations thereof. 
     
     
         13 . The material of  claim 10 , wherein the one or more final reacted solid particles comprise an oxide compound with two or more metals comprising lithium (Li), and a metal selected from the group consisting of cobalt (Co), manganese (Mn), nickel (Ni), aluminum (Al), magnesium (Mg), titanium (Ti), sodium (Na), potassium (K), rubidium (Rb), vanadium (V), cesium (Cs), chromium (Cr), copper (Cu), iron (Fe), and combinations thereof. 
     
     
         14 . The material of  claim 10 , wherein the one or more final reacted solid particles comprise a material selected from the group consisting of a metal oxide, titanium oxide, chromium oxide, tin oxide, copper oxide, aluminum oxide, manganese oxide, iron oxide, a metal oxide with two or more metals, lithium transitional metal oxides, lithium titanium oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel oxide, lithium iron phosphate, lithium cobalt phosphate, lithium manganese phosphate, lithium nickel phosphate, sodium iron oxide, sodium iron phosphate, a metal oxide with three or four intercalated metals, lithium nickel cobalt oxide, lithium nickel manganese oxide, lithium nickel manganese cobalt oxide, Li a Ni b Mn c Co d O e  in layered structures, Li a Ni b Mn c Co d O e  in layered-layered structures, LiNi x Mn y Co z O 2  (where x+y+z=1), LiNi 0.33 Mn 0.33 Co 0.33 O 2 , LiNi 0.6 Mn 0.2 CO 0.2 O 2 , LiNi 0.5 Mn 0.3 Co 0.2 O 2 , LiNi 0.4 Mn 0.4 Co 0.2 O 2 , LiNi 0.7 Mn 0.15 Co 0.15 O 2 , LiNi 0.8 Mn 0.1 Co 0.1 O 2 , a mixed metal oxide with doped metal, Li a (Ni x Mn y Co z )MeO b  (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), Li a (Ni x Mn y Co z )MeO b F c (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), lithium cobalt aluminum oxide, lithium nickel cobalt aluminum oxide, sodium iron manganese oxide, and combinations thereof. 
     
     
         15 . The material of  claim 10 , wherein the first gas-solid mixture is separated into the first type of solid particles using one or more separators selected from the group consisting of cyclones, electrostatic separators, electrostatic precipitators, gravity separators, inertia separators, membrane separators, fluidized beds, classifiers, electric sieves, impactors, particles collectors, leaching separators, elutriators, air classifiers, leaching classifiers, and combination thereof. 
     
     
         16 . The material of  claim 10 , wherein the first type of solid particles are delivered into a gas-solid feeder to form into the second gas-solid mixture, and wherein the gas-solid feeder is selected from the group consisting of a venture feeder, a rotary feeder, a screw feeder, a table feeder, a belt feeder, a vibrating feeder, a tube feeder, and combinations thereof. 
     
     
         17 . A material of a battery cell, comprising:
 one or more final reacted solid particles of a reaction product obtained from a process comprising:
 forming a mixture from a mist of a liquid mixture and a flow of a first gas; 
 drying the mixture at a drying temperature to form into a first gas-solid mixture inside a drying chamber; 
 taking the first gas-solid mixture out of the drying chamber; 
 separating the first gas-solid mixture into a first type of solid particles and a first side product using a first separator; 
 reacting a second gas-solid mixture formed from the first type of solid particles and a flow of a second gas heated to a first reaction temperature and forming a second gas-solid mixture inside a gas-solid feeder; 
 separating the second gas-solid mixture into a second type of solid particles and a second side product by using a second separator; 
 delivering the second type of solid particles into a reactor; 
 forming a third gas-solid mixture from the second type of solid particles and a flow of a third gas heated to a second reaction temperature; 
 reacting the third gas-solid mixtures inside the reactor; and 
 forming the one or more final reacted solid particles. 
   
     
     
         18 . The material of  claim 17 , wherein the first separator is selected from the group consisting of cyclones, electrostatic separators, electrostatic precipitators, gravity separators, inertia separators, membrane separators, fluidized beds, classifiers, electric sieves, impactors, particles collectors, leaching separators, elutriators, air classifiers, leaching classifiers, and combination thereof. 
     
     
         19 . The material of  claim 17 , wherein the gas-solid feeder is selected from the group consisting of a venture feeder, a rotary feeder, a screw feeder, a table feeder, a belt feeder, a vibrating feeder, a tube feeder, and combinations thereof. 
     
     
         20 . The material of  claim 17 , wherein the one or more final reacted solid particles comprise an oxide compound with two or more metals comprising lithium (Li), and a metal selected from the group consisting of cobalt (Co), manganese (Mn), nickel (Ni), aluminum (Al), magnesium (Mg), titanium (Ti), sodium (Na), potassium (K), rubidium (Rb), vanadium (V), cesium (Cs), chromium (Cr), copper (Cu), iron (Fe), and combinations thereof. 
     
     
         21 . The material of  claim 17 , wherein the one or more final reacted solid particles comprise a material selected from the group consisting of a metal oxide, titanium oxide, chromium oxide, tin oxide, copper oxide, aluminum oxide, manganese oxide, iron oxide, a metal oxide with two or more metals, lithium transitional metal oxides, lithium titanium oxide, lithium cobalt oxide, lithium manganese oxide, lithium nickel oxide, lithium iron phosphate, lithium cobalt phosphate, lithium manganese phosphate, lithium nickel phosphate, sodium iron oxide, sodium iron phosphate, a metal oxide with three or four intercalated metals, lithium nickel cobalt oxide, lithium nickel manganese oxide, lithium nickel manganese cobalt oxide, Li a Ni b Mn c Co d O e  in layered structures, Li a Ni b Mn c Co d O e  in layered-layered structures, LiNi x Mn y Co z O 2  (where x+y+z=1), LiNi 0.33 Mn 0.33 Co 0.33 O 2 , LiNi 0.6 Mn 0.2 Co 0.2 O 2 , LiNi 0.5 Mn 0.3 CO 0.2 O 2 , LiNi 0.4 Mn 0.4 Co 0.2 O 2 , LiNi 0.7 Mn 0.15 CO 0.15 O 2 , LiNi 0.8 Mn 0.1 Co 0.1 O 2 , a mixed metal oxide with doped metal, Li a (Ni x Mn y Co z )MeO b  (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), Li a (Ni x Mn y Co z )MeO b F c  (where Me=doped metal of Al, Mg, Fe, Ti, Cr, Zr, or C), lithium cobalt aluminum oxide, lithium nickel cobalt aluminum oxide, sodium iron manganese oxide, and combinations thereof.