Furnace facility and method for manufacturing battery materials

Abstract

A furnace facility for manufacturing battery materials includes: a plurality of process units (12.i), each process unit having a housing (16.i) and a process chamber (14.i) disposed within the housing, wherein each process unit (12.i) is configured such that a process is performed in its process chamber (14.i) under a process atmosphere (18.i) required for the process, wherein the corresponding process material is subjected to heat treatment and / or thermochemical treatment. An atmosphere system (20) is used to generate the process atmosphere (18.i) required for the corresponding process to be performed in each process chamber (14.i). A conveying system (24) is used to convey the process material as process input material (26.i) to be processed into the corresponding process chamber (14.i), and after the process is performed in the process chamber (14.i), the process material is conveyed out of the process chamber (14.i) as processed process output material (30.i). At least two process chambers (14.i, 14.i+1) are connected to each other via an airlock device (32.i), wherein continuous processing is performed in the process chambers (14.i, 14.i+1) under process atmospheres (18.i, 18.i+1) different from each other and with different compositions, wherein the two process chambers (14.i, 14.i+1) define, relative to each other, a front-end process chamber (34) for front-end processing and a subsequent process chamber (36) for subsequent processing. A conveying system (24) is configured to convey the processed process output material (30.i) of the front-end processing from the front-end process chamber (34i) to the airlock device (32.i), and from there to the subsequent process chamber (36.i+1) as process input material to be processed for the subsequent processing. The invention also provides a method for manufacturing battery materials.

Description

Technical Field

[0001] 1. Field of Invention

[0002] This invention relates to a furnace facility for manufacturing battery materials, comprising:

[0003] a) Multiple process units, each having a housing and a process chamber disposed therein, wherein each process unit is configured such that the process can be performed in its process chamber under the process atmosphere required for the process, wherein the process material is subjected to heat treatment and / or thermochemical treatment during the process.

[0004] b) Atmosphere system: The atmosphere system can generate the process atmosphere required for the corresponding processing procedure in each process chamber.

[0005] c) Conveying system: The conveying system can transport the process materials as process input materials to the corresponding process chambers, and after the processing is carried out in the process chambers, the process materials are transported out of the process chambers as processed process output materials.

[0006] The present invention also relates to a method for manufacturing battery materials in a furnace facility, wherein the corresponding process materials are subjected to heat treatment and / or thermochemical treatment during processing in multiple process units. Background Technology

[0007] 2. Description of the prior art

[0008] The manufacture of battery materials, such as battery anode materials, involves multiple sequentially executed processes in which particulate materials are subjected to heat treatment and / or thermochemical treatment in specific process atmospheres required for each process. The particulate materials are typically powder materials.

[0009] The process atmosphere can be an inert atmosphere or a chemically reactive atmosphere, where a chemically reactive atmosphere is or includes process gases. The latter can also be air, which may be conditioned, for example, by temperature control and dehumidification.

[0010] The manufacturing process is divided into an activation zone with multiple processing steps and a permeation zone with multiple processing steps.

[0011] To ensure a smooth process flow and to obtain the required high-quality battery materials at the end of the process, it is extremely important to ensure that, in two consecutive processes performed in different process atmospheres, these two different process atmospheres do not come into contact with each other in a way that would safely interfere with the process or facility.

[0012] Discontinuous furnace facilities are known in the market, where the process chamber is used for multiple processes and operates in a batch processing manner. Here, after the first process is completed, the first process atmosphere used for that first process is replaced in the process chamber with a second process atmosphere of different composition used for the second process. This batch processing can be very energy-intensive, especially when the furnace facility must be substantially or completely cooled before the atmosphere change and reheated afterward. Furthermore, the preceding process atmosphere must be reliably removed from the entire volume of the process chamber before a process atmosphere can be supplied for subsequent processes.

[0013] As an alternative to this batch processing facility, if a separate process unit is used for each process (as is the case in the furnace facility of the type described at the beginning), then in commercially known furnace facilities, multiple process units are designed as spatially separated process furnaces, each with its own inlet and outlet airlocks, necessitating the transfer of material from one furnace to another. Here, the material is typically cooled and must subsequently be reheated. Therefore, a relatively large amount of energy is also required in this case. Furthermore, the structural investment is higher.

[0014] Therefore, the object of the present invention is to provide a furnace facility and method for manufacturing battery materials, which provides energy advantages and preferably also structural advantages. Summary of the Invention

[0015] For the type of furnace facility described at the beginning, this objective is achieved in the following way:

[0016] d) At least two process chambers are connected to each other by an airlock device, wherein continuous processing is performed in these process chambers under process atmospheres that are different from each other and have different compositions, wherein the two process chambers define each other as a preceding process chamber for a preceding process and a subsequent process chamber for a subsequent process.

[0017] e) The conveying system is configured to convey the processed process output material of the preceding process from the preceding process chamber to the airlock device, and from there convey it as the process input material to be processed in the subsequent process chamber.

[0018] According to the present invention, although the corresponding process atmospheres required for different processing steps vary considerably in their composition and temperature, it is still possible to convey the material to be processed through a continuous process chamber and process it therein in a continuous process. Thus, there is a substantially direct transition from one processing step to the next, thereby shortening the transition time, and, for example, the heated material does not cool down, which would otherwise require reheating in subsequent processing if necessary.

[0019] For the manufacture of battery materials, and especially for the manufacture of battery anode materials, the advantages are:

[0020] a) The furnace facility provides an activation furnace system for heat treatment and / or thermochemical treatment of materials, the activation furnace system comprising at least two of the following process units:

[0021] a.1) A heat treatment apparatus for heat-treating materials, comprising:

[0022] a.1-1) Shell, in which a process chamber is housed, the process chamber defining the heat treatment chamber;

[0023] a.1-2) Heat treatment atmosphere apparatus, which can generate a heat treatment atmosphere with a heat treatment temperature, especially between 30°C and 500°C, in a heat treatment chamber;

[0024] a.1-3) Heat treatment conveying device, which can transport process materials as heat treatment input materials to the heat treatment chamber, and after the heat treatment process, transport the process materials as dried heat treatment output materials out of the heat treatment chamber.

[0025] a.2) A pyrolysis apparatus for pyrolyzing materials, comprising:

[0026] a.2-1) Shell, in which a process chamber is disposed, the process chamber defining the pyrolysis chamber;

[0027] a.2-2) Pyrolysis atmosphere apparatus, which can generate a pyrolysis atmosphere with a pyrolysis temperature, especially between 100°C and 1000°C, in the pyrolysis chamber;

[0028] a.2-3) Pyrolysis conveying device: The pyrolysis conveying device can transport the process material as the pyrolysis input material to be pyrolyzed into the pyrolysis chamber, and after the pyrolysis process, transport the process material as the pyrolysis output material out of the pyrolysis chamber.

[0029] a.3) An activation apparatus for activating materials, comprising:

[0030] a.3-1) Shell, in which a process chamber is housed, the process chamber defining the activation chamber;

[0031] a.3-2) Activation atmosphere device, which can generate an activation atmosphere with an activation temperature, especially between 500°C and 1200°C, in the activation chamber;

[0032] a.3-3) Activation conveying device: The activation conveying device can transport the process material as the activation input material to be activated into the activation chamber, and after the activation process, transport the process material as the activated output material out of the activation chamber.

[0033] in

[0034] The upstream process chamber and the downstream process chamber are formed by a heat treatment chamber and a pyrolysis chamber, or by a pyrolysis chamber and an activation chamber.

[0035] and / or

[0036] b) The furnace facility provides a permeation furnace system for heat treatment and / or thermochemical treatment of materials, the permeation furnace system comprising at least two of the following process units:

[0037] b.1) A temperature control device for heating materials, comprising:

[0038] b.1-1) Shell, in which a process chamber is housed, the process chamber defining a temperature control chamber;

[0039] b.1-2) Temperature-controlled atmosphere device, which can generate a temperature-controlled atmosphere with a temperature-controlled temperature, especially between 30°C and 600°C, in a temperature-controlled room;

[0040] b.1-3) Temperature regulating conveying device: The temperature regulating conveying device can transport the process material as the temperature regulating input material to be heated into the temperature regulating chamber, and after the temperature regulating process, transport the process material as the heated temperature regulating output material out of the temperature regulating chamber.

[0041] b.2) A permeation apparatus for permeating a substrate into a material, comprising:

[0042] b.2-1) Shell, in which a process chamber is housed, the process chamber defining the permeation chamber;

[0043] b.2-2) Permeation atmosphere apparatus, which can generate a permeation atmosphere with a permeation temperature, especially between 300°C and 600°C, in the permeation chamber;

[0044] b.2-3) Permeation transport device: The permeation transport device can transport the process material as the permeation input material to be permeated into the permeation chamber, and after the permeation process, transport the process material as the permeated output material out of the permeation chamber.

[0045] b.3) A passivation apparatus for passivating materials, comprising:

[0046] b.3-1) Shell, in which a process chamber is housed, the process chamber defining the passivation chamber;

[0047] b.3-2) Passivation atmosphere apparatus, which can generate a passivation atmosphere with a passivation temperature in the passivation chamber;

[0048] b.3-3) Passivation conveying device: The passivation conveying device can transport the process material as the activation input material to be activated into the passivation chamber, and after the passivation process, the process material is transported out of the passivation chamber as the passivated output material.

[0049] b.4) A cooling device for cooling materials, comprising:

[0050] b.4-1) Shell, in which a process chamber is housed, the process chamber defining a cooling chamber;

[0051] b.4-2) Cooling atmosphere device, which can generate a cooling atmosphere with a cooling temperature, especially between 600°C and 30°C, in the cooling chamber;

[0052] b.4-3) Cooling conveying device: This device transports process materials as input materials to be cooled into the cooling chamber, and after the cooling process, it transports the process materials out of the cooling chamber as cooled output materials.

[0053] in

[0054] The upstream process chamber and the downstream process chamber are formed by a conditioning chamber and a permeation chamber, or by a permeation chamber and a passivation chamber, or by a passivation chamber and a cooling chamber, or by a cooling chamber and a passivation chamber.

[0055] The activation furnace system here covers the corresponding processing of the activation section of the manufacturing process, and the permeation furnace system here covers the corresponding processing of the permeation section of the manufacturing process.

[0056] Regarding airlock equipment, the advantages are:

[0057] a) An activation furnace system is provided, and in the activation furnace system, one, more or all airlock devices located between the upstream process chamber and its downstream process chamber are designed as single-chamber airlocks;

[0058] and / or

[0059] b) A permeation furnace system is provided, and in the permeation furnace system, one, more or all airlock devices located between the upstream process chamber and its downstream process chamber are designed as double-chamber airlocks.

[0060] In practice, the process atmosphere in the process chamber of an activation furnace system can be mixed without negatively impacting process control, and two consecutive process chambers can have the same composition if necessary. Therefore, isolating the process chambers by a single-chamber airlock is sufficient. If isolation of the process atmosphere is required, it is advantageous that the door of the single-chamber airlock can be hermetically closed, allowing the airlock chamber to be evacuated and purged with purge gas if necessary.

[0061] For single-chamber airlocks in hot zones, atmosphere isolation can be achieved by injecting additional nitrogen into the single-chamber airlock when or before opening the airlock.

[0062] Especially in permeation furnace systems, where a more corrosive process atmosphere may exist, it is advantageous to reliably ensure the isolation of the process atmosphere between the upstream and downstream process chambers through appropriate dual-chamber airlocks.

[0063] A dual-chamber airlock is characterized by two airlock chambers that are isolated from each other by connecting gate devices that form a flow barrier between the upstream and downstream process chambers. Ideally, this flow barrier provides an airtight seal between the two process chambers. Dual-chamber airlocks are particularly advantageous, for example, in corrosive atmospheres. Dual-chamber airlocks can, but are not necessarily, located between all interconnected upstream and downstream process chambers. A dual-chamber airlock always has three airlock gate devices: an input gate for entering the first airlock chamber, a connecting gate between the two airlock chambers, and an output gate for exiting the second airlock chamber, arranged along the passage direction. Typically, the airlock chambers are subjected to a slight overpressure.

[0064] In order to achieve comprehensive and continuous operation of the corresponding furnace system, it is particularly advantageous that:

[0065] a) The activation furnace system is provided in such a way that the heat treatment chamber forms a first forward process chamber, the pyrolysis chamber forms a first subsequent process chamber and a second forward process chamber, and the activation chamber forms a second subsequent process chamber.

[0066] and / or

[0067] b) The permeation furnace system is provided in such a manner that the conditioning chamber forms a first upstream process chamber, the permeation chamber forms a first downstream process chamber and a second upstream process chamber, and

[0068] b1) A passivation chamber is formed or is capable of forming a second subsequent process chamber and a third preceding process chamber, and a cooling chamber is formed or is capable of forming a third subsequent process chamber;

[0069] or

[0070] b2) A cooling chamber is formed or is capable of forming a second subsequent process chamber and a third preceding process chamber, and a passivation chamber is formed or is capable of forming a third subsequent process chamber.

[0071] Therefore, in these cases, the activation or penetration phases of the manufacturing process, or both, can be performed essentially as a continuous process.

[0072] A permeation furnace system can be provided in such a way that the permeation furnace system includes a first passivation chamber and a second passivation chamber, wherein the first passivation chamber is connected to a cooling chamber via an airlock device, and the cooling chamber is connected to the second passivation chamber via an airlock device.

[0073] In this way, the permeation furnace system achieves two alternative passivation paths, which will be explained again later.

[0074] An activation furnace system is advantageously provided such that multiple process zones are defined along the conveying direction within the activation chamber, in which different temperatures are generated and maintained. In these activation processes, the process material must or should be treated in the same activation atmosphere but at different temperatures. Advantageously, the process zones of the activation chamber include an activation zone and one or more cooling zones, where the activation temperature is present in the activation zone and temperatures below the activation temperature are present in the cooling zones.

[0075] Given the availability of appropriate process equipment, the corresponding processing can be performed with particularly high efficiency if the following conditions are met:

[0076] a) The heat treatment atmosphere apparatus provides an inert gas atmosphere, especially an atmosphere composed of nitrogen (N2), as the heat treatment atmosphere.

[0077] and / or

[0078] b) The pyrolysis atmosphere apparatus provides an inert gas atmosphere, especially an atmosphere composed of nitrogen (N2), as the pyrolysis atmosphere;

[0079] and / or

[0080] c) The activating atmosphere device is or contains oxygen compounds as the activating atmosphere;

[0081] and / or

[0082] d) The temperature control atmosphere device provides an inert gas atmosphere, especially an atmosphere composed of nitrogen (N2), as the temperature control atmosphere;

[0083] and / or

[0084] e) The permeation atmosphere apparatus provides an atmosphere as a permeation atmosphere, namely: the atmosphere itself provides silicon or silicon compound as a permeation substrate;

[0085] and / or

[0086] f) The passivation atmosphere apparatus provides a passivation atmosphere comprising or being a hydrocarbon, and particularly having a passivation temperature between 300°C and 600°C, or provides a passivation atmosphere comprising or being air or a nitrogen / air mixture, and particularly having a passivation temperature between 30°C and 150°C as the passivation atmosphere.

[0087] and / or

[0088] g) The cooling atmosphere device provides nitrogen (N2) as the cooling atmosphere.

[0089] For methods of the type described at the beginning, the above objective is achieved by using a furnace facility having one, more, or all of the features described herein. Attached Figure Description

[0090] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings. In the drawings:

[0091] Figure 1 A schematic top view of an activation furnace system illustrating furnace facilities for heat treatment or thermochemical treatment of materials;

[0092] Figure 2 A schematic top view of a permeation furnace system shown, illustrating furnace facilities for heat treatment or thermochemical treatment of materials. Detailed Implementation

[0093] 1. Furnace facilities

[0094] exist Figure 1 and Figure 2 In this context, 10 generally represents a furnace facility having multiple process units 12.i (where i = 1 to n) with multiple process chambers 14.i (where i = 1 to n), each for manufacturing battery materials, where n represents the total number of process units 12.i. In this embodiment, the battery material is a particulate battery anode material, which is obtained herein in the form of material powder.

[0095] Each process chamber 14.i is housed in its respective housing 16.i.

[0096] For components described herein and below, process apparatus 12.i specifies an index of the corresponding component belonging to or associated with process apparatus 12.i. Accordingly, for example, the process chamber of process apparatus 12.4 is provided with reference numeral 14.4, and the associated housing is provided with reference numeral 16.4.

[0097] Each process unit 12.i is configured such that the process can be performed in its process chamber 14.i under the process atmosphere 18.i required for the process, during which the material is subjected to heat treatment and / or thermochemical treatment.

[0098] Using the atmosphere system 20, a process atmosphere 18.i required for the corresponding processing to be performed is generated and maintained in each process chamber 14.i, and the corresponding process atmosphere 18.i has the required composition and temperature. For this purpose, the atmosphere system 20 includes a corresponding process atmosphere device 22.i for each process chamber 14.i, which allows the process atmosphere device to set the required process chamber temperature in each process chamber 14.i.

[0099] Each process atmosphere apparatus 22.i includes components necessary for this purpose but not shown separately. These components include: supply and discharge lines connected to the corresponding process chamber 14.i; conveying devices, such as fans; heating devices; and devices for regulating the atmosphere, etc., by which the corresponding airflow can be generated, supplied, drawn in, circulated, replenished, and regulated. For example, in order to generate and maintain the process atmosphere 18.i, it also includes: applying process gases to the materials to perform the processing; for this purpose, the process apparatus 12.i may include a specially equipped nozzle system. If compounds are generated during the processing, these compounds naturally also contribute to the formation of the corresponding process atmosphere.

[0100] Using the conveying system 24, process materials are transported as process input materials 26.i to the corresponding process chambers 14.i. After the processing is performed in the process chambers 14.i, the process materials are transported out of the process chambers 14.i as processed process output materials 30.i. For this purpose, the conveying system 24 includes a corresponding process conveying device 28.i for each process chamber 14.i.

[0101] When the process output material 30.i is conveyed to the subsequent process chamber 14.i+1 for another processing, the process output material 30.i is then used to define the process input material 26.i+1 for the subsequent process chamber 14.i+1.

[0102] The furnace facility 10 is characterized in that at least two process chambers 14.i and 14.i+1 are connected to each other by an airlock device 32.i, in which continuous processing is performed under process atmospheres 18.i and 18.i+1 different from each other, wherein the two process chambers 14.i and 14.i+1 define, relative to each other, a front process chamber 34 for a preceding process and a subsequent process chamber 36 for a subsequent process.

[0103] Thus, the housing 16.i of the preceding process chamber 14.i or 34, the housing of the airlock device 32.i, and the housing of the subsequent process chamber 14.i+1 or 36 together form a coherent housing unit, which is expanded by further adding the airlock device 32.i and the housing of the process chamber 14.i as necessary.

[0104] Furthermore, the conveying system 24 is configured to convey the processed process output material 30.i from the front-end process chamber 34 to the airlock device 32.i, and from there to the subsequent process chamber 36 as the process input material 26.i to be processed in the subsequent process.

[0105] In this embodiment, the furnace facility 10 includes a first furnace system that provides an activation furnace system 38 for heat treatment and thermochemical treatment of materials. Figure 1 An embodiment of such an activation furnace system 38 is shown, which defines three process chambers 14.1, 14.2 and 14.3 of the furnace facility 10.

[0106] Furthermore, in this embodiment, the furnace facility 10 includes a second furnace system that provides a permeation furnace system 40 for heat treatment and thermochemical treatment of materials within the permeation furnace system. Figure 2 An embodiment of such a permeation furnace system 40 is shown, wherein there are five other process units of the furnace facility 10, labeled 12.4, 12.5, 12.6, 12.7 and 12.8 respectively.

[0107] Therefore, in the furnace facility 10 described herein, the total number i = 1 to 8, where n = 8.

[0108] The following will describe which process units 12.i are present in furnace systems 38 and 40, and the components and parts that belong to and are associated with these process units. Here, for the names of specific reference numerals with specific index i, the term "process" is replaced with "specific function" and "specific process objective".

[0109] 2. Activation furnace system

[0110] In this sense Figure 1The activation furnace system 38 shown includes a heat treatment apparatus 12.1 for heat treating the heat treatment input material 26.1, the heat treatment apparatus having a heat treatment chamber 14.1 disposed in the housing 16.1. Therefore, the process apparatus 12.1 is the heat treatment apparatus 12.1, and the term "process" is replaced by "heat treatment".

[0111] Accordingly, the heat treatment apparatus 12.1 also includes a heat treatment atmosphere apparatus 22.1 and a heat treatment conveying apparatus 28.1. The heat treatment atmosphere apparatus generates a heat treatment atmosphere 18.1 with a heat treatment temperature. The heat treatment conveying apparatus conveys the heat treatment input material 26.1 to be heat treated to the heat treatment chamber 14.1 and conveys the dried heat treatment output material 30.1 out of the heat treatment chamber 14.1.

[0112] Furthermore, the activation furnace system 38 includes a pyrolysis device 12.2 for pyrolyzing the pyrolysis input material 26.2, the pyrolysis device having a pyrolysis chamber 14.2 disposed within the housing 16.2. The pyrolysis device 12.2 also includes a pyrolysis atmosphere device 22.2 and a pyrolysis conveying device 28.2. The pyrolysis atmosphere device generates a pyrolysis atmosphere 18.2 with a pyrolysis temperature, and the pyrolysis input material 26.2 to be pyrolyzed is conveyed to the pyrolysis chamber 14.2 by the pyrolysis conveying device, and the pyrolysis output material 30.2 after pyrolysis is conveyed out of the pyrolysis chamber 14.2.

[0113] As a third process unit, the activation furnace system 38 includes an activation device 12.3 for activating the input material 26.3, the activation device having an activation chamber 14.3 disposed in a housing 16.3. The activation device 12.3 also includes an activation atmosphere device 22.3 and an activation conveying device 28.3, the activation atmosphere device generating an activation atmosphere 18.3 with an activation temperature, the activation input material 26.2 to be activated being conveyed to the heat treatment chamber 14.3 by the activation conveying device, and the activated output material 30.3 being conveyed out of the activation chamber 14.3.

[0114] The heat treatment device 12.1 is connected to the pyrolysis device 12.2 via the airlock device 32.1, and the pyrolysis device is connected to the activation device 12.3 via the airlock device 32.2.

[0115] An input airlock 42 is present at the input end of the activation furnace system 10, which limits the inlet to the heat treatment apparatus 12.1. An output airlock 44 is present at the output end of the activation furnace system 10, and therefore at the output end of the activation apparatus 12.3. The input airlock 42 and the output airlock 44 are both single-chamber airlocks with input and output gates, respectively, which are known in themselves, but the input and output gates are not individually labeled.

[0116] The material to be processed is conveyed through the activation furnace system 38 on the supporting structure 46. (As if using...) Figure 1 As can be seen from the side view of the support structure 46a, the support structure may include, for example, a plurality of transport channels 48 arranged in a plurality of transport layers.

[0117] The activation furnace system 38 is designed as a continuous furnace system and, from a conveying technology perspective, as a pusher furnace. For this purpose, the conveying system 24 includes multiple hydraulic pushers 50, which are shown schematically. A support structure 46 loaded with the material to be processed is pushed by the pushers 50 on a conveyor base plate 52 present in each process chamber 14.i in a manner known per se. The conveyor base plate 52 can be designed as a pusher track, in which the support structure 46 is positioned on a so-called pusher plate, which is then pushed along the pusher track. Alternatively, the conveyor base plate 52 can also be designed as a roller conveyor, for example.

[0118] In this embodiment, the heat treatment input material 26.1 in powder form is transported to the heat treatment chamber 14.1 through the input airlock 42.

[0119] In the heat treatment chamber 14.1 of the heat treatment apparatus 12.1, a heat treatment atmosphere 18.1 with a heat treatment temperature is generated by means of a heat treatment atmosphere device 22.1. In this embodiment, the heat treatment temperature is between 30°C and 500°C. Under the heat treatment atmosphere 18.1, the heat treatment input material 26.1 is correspondingly heated and thereby dried as it passes through the heat treatment apparatus 12.1, resulting in a dried heat treatment output material 30.1 after passing through the heat treatment chamber 14.1. If necessary, the heat treatment input material 26.1 is a mixture of materials whose components can combine during heat treatment. When heat treatment is performed on the heat treatment input material 26.1, water (H2O) and ammonia (NH3) may be generated. The heat treatment atmosphere 18.1 is in particular an inert gas atmosphere, and in this embodiment, it is an atmosphere composed of nitrogen (N2).

[0120] Subsequently, the heat treatment output material 30.1 is transported to the pyrolysis unit 14.2 as pyrolysis input material 26.2 through the airlock device 32.1.

[0121] In the pyrolysis chamber 14.2 of the pyrolysis apparatus, a pyrolysis atmosphere 18.2 is generated by a pyrolysis atmosphere device 22.2, and the pyrolysis input material 26.2 is pyrolyzed at a pyrolysis temperature under this atmosphere. Thus, in this embodiment, carbon material is produced from the heat-treated output material 30.1 at a temperature between 100°C and 1000°C, which defines the pyrolysis output material 30.2 after pyrolysis. During the pyrolysis of the heat-treated output material 30.1, hydrocarbons C may be generated, for example. x Hy Hydrogen cyanide (HCN) and nitrogen oxides (NO and NO2). The pyrolysis atmosphere 18.2 is particularly an inert gas atmosphere, and in this embodiment, it is an atmosphere composed of nitrogen (N2).

[0122] In the pyrolysis chamber 14.2, multiple process zones in the form of pyrolysis zones 54 are defined along the conveying direction, in which the temperatures required for the pyrolysis process are generated. In this embodiment, the process material is gradually heated to the pyrolysis temperature.

[0123] The pyrolysis output material 30.2 then reaches the airlock device 32.2, and along this path, it enters the activation chamber 14.3 of the activation device 12.3 as the activation input material 26.3.

[0124] In activation chamber 14.3, an activation atmosphere 18.3 with an activation temperature is generated by activation atmosphere device 22.3, and the process material is activated under the activation atmosphere. Multiple process zones are defined in activation chamber 14.3 along the conveying direction, in which different temperatures required for the activation process are generated and maintained. In this embodiment, activation atmosphere 18.3 is or contains an oxygen compound, through which an activated carbon material in the form of porous carbon is generated, which exists in the form of a cake-shaped carbon material.

[0125] In this embodiment, the process zone along the conveying direction includes both an activation zone 56, in which an activation temperature is present, and a cooling zone 58, with a temperature lower than that of the activation zone. In the activation zone 56, a water vapor atmosphere with an activation temperature between 500°C and 1200°C is first generated. This is followed by two cooling zones 58, in which the process material is gradually cooled. Subsequently, the process material, in this case the activated carbon material, arrives at the output gas gate 44 of the activation furnace system 38 as the activated output material 30.3. In a variant, there is no cooling zone 58, and no cooling is performed accordingly.

[0126] Structurally, the airlock device 32.i is characterized by an airlock input chamber 60 and an airlock output chamber 62. In the activation furnace system 40, only single-chamber airlocks exist, in which the corresponding airlock input chamber 60 and the corresponding airlock output chamber 62 together form an airlock chamber. For the double-chamber airlock, which will be described further below, a connecting door device 64 is arranged between the corresponding airlock input chamber 60 and the corresponding airlock output chamber 62.

[0127] In addition, an input door device 66 is always present in the airlock input chamber 60, and an output door device 68 is always present in the airlock output chamber 62.

[0128] To achieve the airlock function, each airlock device 32.i also includes an airlock atmosphere device 70, which can establish and modify the atmosphere in airlock chambers 60 and 62, and can evacuate the airlock chambers when necessary, such as as required for process materials to pass through the airlock. The airlock devices 32.i of the activation furnace system 40 are respectively defined as single-chamber airlocks or double-chamber airlocks.

[0129] The airlock device 32.i is designed as a transverse conveying airlock, and for this purpose includes a transverse conveyor 72 in the form of a pusher conveyor 50 as part of the conveying system 24.

[0130] After passing through the activation chamber 14.3, the obtained activated output material 30.3, i.e. the activated carbon material in this embodiment, is conveyed out of the activation furnace system 38 through the output airlock 44.

[0131] If necessary, the activated output material 30.3 is first subjected to intermediate treatment to prepare it for the subsequent permeation process. For example, the material can be ground so that the material subsequently supplied to the permeation furnace system 40 is in the form of a powder. In this embodiment, this is followed by activated carbon powder.

[0132] 3. Permeation Furnace System

[0133] for Figure 2 The permeation furnace system 40 shown corresponds functionally to the components and parts of the activation furnace system 48 that have already been described, and these components and parts are given the same reference numerals. Therefore, the above description applies accordingly by analogy.

[0134] Figure 2 The permeation furnace system 40 shown includes a temperature control device 12.4 for heating the temperature-controlled input material 26.4, the device having a temperature-controlled chamber 14.4 housed within a housing 16.4. The temperature control device 12.4 also includes a temperature-controlled atmosphere device 22.4 and a temperature-controlled conveying device 28.4. The atmosphere device generates a temperature-controlled atmosphere 18.4 with a controlled temperature, the conveying device delivers the temperature-controlled input material 26.4 to be heated into the temperature-controlled chamber 14.4, and the conveying device delivers the heated temperature-controlled output material 30.4 (with a controlled temperature between 30°C and 600°C) out of the chamber 14.4. In this embodiment, the temperature-controlled atmosphere is an inert gas atmosphere, specifically an atmosphere composed of nitrogen (N2).

[0135] Furthermore, the permeation furnace system 40 includes a permeation device 12.5 for permeating a substrate into a permeation input material 26.5, the permeation device having a permeation chamber 14.5 disposed within a housing 16.5. The permeation device 12.5 also includes a permeation atmosphere device 22.5 and a permeation delivery device 28.5, the permeation atmosphere device generating a permeation atmosphere 18.5 with a permeation temperature, the permeation input material 26.5 to be permeated being delivered to the permeation chamber 14.5 by the permeation delivery device, and the permeated permeation output material 30.5 being delivered out of the permeation chamber 14.5.

[0136] Chemical vapor infiltration is performed in infiltration apparatus 12.5. In this embodiment, the infiltration temperature is between 300°C and 600°C, and the infiltration atmosphere provides silicon (Si) or a silicon compound as the infiltration substrate. Specifically, the silicon (Si) or silicon compound is provided in gaseous form. During this process, silicon or a silicon compound is also infiltrated onto the inner surface of this porous carbon as the infiltration substrate, and a carbon-silicon composite material is produced, which defines the infiltrated permeate material 30.5.

[0137] As another process unit of the permeation furnace system 40 Figure 2 A passivation apparatus 12.6 for passivating a passivation input material 26.6 is shown. The passivation apparatus has a passivation chamber 14.6 disposed in a housing 16.6. The passivation apparatus 12.6 also includes a passivation atmosphere device 22.6 and a passivation conveying device 28.6. The passivation atmosphere device generates a passivation atmosphere 18.6 with a passivation temperature. The passivation input material 26.6 to be passivated is conveyed to the heat treatment chamber 14.6 by the passivation conveying device, and the passivated output material 30.6 is conveyed out of the passivation chamber 14.6. In this embodiment, the passivation atmosphere 18.6 contains or contains hydrocarbons. The passivation temperature is particularly between 300°C and 600°C. Hydrocarbons C are particularly generated during the passivation process. x H y Therefore, a stabilized carbon-silicon composite material is used as a passivation output material 30.6.

[0138] Furthermore, the permeation furnace system 40 includes a process device in the form of a cooling device 12.7 for cooling the input material 26.7. The cooling device has a cooling chamber 14.7 disposed within a housing 16.7. The cooling device 12.7 also includes a cooling atmosphere device 22.7 and a cooling conveying device 28.7. The cooling atmosphere device generates a cooling atmosphere 18.7 with a cooling temperature. The cooling input material 26.7 to be cooled is conveyed to the cooling chamber 14.7 by the cooling conveying device, and the cooled output material 30.7 is conveyed out of the cooling chamber 14.7. The cooling temperature is between 600°C and 30°C, and in any case, it is lower than the temperature of the input material 26.7 when it enters the cooling chamber 14.7. Here, the cooled output material 30.7 has a temperature of 30°C after the cooling process. In this embodiment, the cooling atmosphere 18.7 is nitrogen (N2).

[0139] also, Figure 2 An alternative passivation device 12.8, serving as a process apparatus for the permeation furnace system 40, is also shown for passivating the passivation input material 26.8. The passivation device has a passivation chamber 14.8 housed within a housing 16.8. The passivation device 12.8 further includes a passivation atmosphere device 22.8 and a passivation conveying device 28.8. The passivation atmosphere device generates a passivation atmosphere 18.8 with a passivation temperature. The passivation input material 26.8 to be passivated is conveyed to the passivation chamber 14.8 by the passivation conveying device, and the passivated output material 30.8 is conveyed out of the passivation chamber 14.8. For the passivation device 12.8, the passivation atmosphere 18.8 is or contains air or a nitrogen / air mixture and particularly has a passivation temperature between 150°C and 30°C. Thus, a stabilized carbon-silicon composite material is also used as the passivation output material 30.6.

[0140] Whenever there are different process atmospheres with different compositions in the upstream process chamber 14.i and the downstream process chamber 14.i+1, the corresponding airlock device 32.i is configured to ensure strict atmosphere isolation between the two process chambers 14.i and 14.i+1.

[0141] The airlock devices 32.4, 32.5 and 32.6 of the permeation furnace system 40 are defined as double-chamber airlocks or three-door airlocks, respectively, while the airlock device 32.7 between the cooling device 12.7 and the alternative passivation device 12.8 is defined as a single-chamber airlock or a double-door airlock.

[0142] For the dual-chamber airlock, the aforementioned connecting door device 64 is present. The corresponding airlock atmosphere device 70 is configured to generate an atmosphere in the airlock input chamber 60 corresponding to the process atmosphere 18.i in the preceding process chamber 14.i, and then replace this atmosphere with an atmosphere corresponding to the process atmosphere 18.i+1 in the subsequent process chamber 14.i+1. A process atmosphere 18.i+1 is also generated in the airlock output chamber 62, so that when the connecting door device 64 is open, the process material can be transferred from the airlock input chamber 60 to the airlock output chamber 62 under the process atmosphere 18.i+1 of the subsequent process chamber 14.i+1. The temperature control device 12.4 is connected to the permeation device 12.5 via the airlock device 32.4, the permeation device is connected to the passivation device 12.6 via the airlock device 32.5, and the passivation device is connected to the cooling device 12.7 via the airlock device 32.6.

[0143] An input airlock 74 is present at the input end of the permeation furnace system 40, which restricts access to the temperature control device 12.4. An output airlock 76 is present at the output end of the permeation furnace system 40, and therefore (in this embodiment) at the output end of the passivation device 12.8.

[0144] The passivation device 12.8 includes its own conveying device 28.8 in the form of a pusher conveyor 50. For this reason, an airlock device 32.6 exists between the cooling device 12.7 and the passivation device 12.8. Unlike airlocks 32.4, 32.5 and 32.6, this airlock device is not designed as a double-chamber airlock with a connecting gate device in the middle, but as a single-chamber airlock. However, this single-chamber airlock is also designed as a transverse conveying airlock to ensure the transfer from the cooling conveying device 28.7 to the passivation conveying device 28.8.

[0145] Passivation units 12.6 and 12.8 can be selectively used for passivation; that is, passivation of the process material can be selectively performed in either passivation unit 12.6 or passivation unit 12.8. When passivation of the process material is performed in passivation unit 12.6, passivation unit 12.8 operates in a neutral mode and is supplied with an air environment at approximately the same temperature as that in the upstream cooling chamber 14.7. Conversely, when passivation of the process material is performed in passivation unit 12.8, passivation unit 12.6 operates in the corresponding neutral mode, wherein the passivation unit is subsequently filled with a nitrogen atmosphere at a temperature lower than or gradually lower than that in the upstream permeation chamber 14.5.

[0146] In this embodiment, the dual-chamber airlock 32.5 located between the permeation chamber 14.5 and the passivation chamber 14.6 is also used to increase the temperature of the permeation output material 30.5; subsequently, the passivation input material 26.6 is conveyed to the passivation chamber 14.6 at this temperature. Furthermore, in this embodiment, the dual-chamber airlock 32.6 located between the passivation chamber 14.6 and the cooling chamber 14.7 is used for pre-cooling, during which the temperature of the passivation output material 30.6 is reduced; subsequently, the cooled input material 26.7 is conveyed to the cooling chamber 14.7 at this temperature.

[0147] The furnace scheme according to the invention enables the continuous manufacturing process of battery materials to be performed in an efficient, energy-saving and resource-saving manner, characterized by multiple process steps with different requirements and performed under different process atmospheres.

[0148] In variants not shown separately, the furnace facility 10 can also be designed as a fully integrated continuous furnace by coupling the two furnace systems 38 and 40 in terms of conveying and process technology using connecting devices. Specifically, in this embodiment, an airlock device can be provided between the activation device 12.3 and the temperature control device 12.4, with an intermediate station provided if necessary for grinding the material obtained from the activation process.

Claims

1. A furnace facility for manufacturing battery materials, comprising: a) A plurality of process units (12.i), each having a housing (16.i) in which a process chamber (14.i) is disposed, wherein each process unit (12.i) is configured such that the processing is performed in its process chamber (14.i) under a process atmosphere (18.i) required for the processing, wherein the corresponding process material is subjected to heat treatment and / or thermochemical treatment; b) Atmosphere system (20), which enables the generation of the process atmosphere (18.i) required for the corresponding process to be performed in each process chamber (14.i). c) A conveying system (24) is used to convey process materials as process input materials (26.i) to the corresponding process chambers (14.i), and after the processing is performed in the process chambers (14.i), the process materials are conveyed out of the process chambers (14.i) as processed process output materials (30.i). Its features are, d) At least two process chambers (14.i, 14.i+1) are connected to each other by an airlock device (32.i), wherein a continuous processing is performed in the process chambers (14.i, 14.i+1) under process atmospheres (18.i, 18.i+1) that are different from each other and have different compositions, wherein the two process chambers (14.i, 14.i+1) define a preceding process chamber (34) for a preceding process and a subsequent process chamber (36) for a subsequent process relative to each other. e) The conveying system (24) is configured to convey the processed process output material (30.i) of the preceding process from the preceding process chamber (34i) to the airlock device (32.i) and from there to the subsequent process chamber (36.i+1) as the process input material to be processed for the subsequent process.

2. The furnace facility according to claim 1, characterized in that, a) The furnace facility provides an activation furnace system (38) for heat treatment and / or thermochemical treatment of materials, the activation furnace system comprising at least two of the following process units (12.i): a.1) A heat treatment apparatus (12.1) for heat treating materials, comprising: a.1-1) A housing (16.1) in which a process chamber is disposed, the process chamber defining a heat treatment chamber (14.1). a.1-2) Heat treatment atmosphere apparatus (22.1), which enables the generation of a heat treatment atmosphere (18.1) having a heat treatment temperature, particularly between 30°C and 500°C, in the heat treatment chamber (14.1). a.1-3) Heat treatment conveying device (28.1), which can convey process material as heat treatment input material (26.1) to the heat treatment chamber (14.1) and after the heat treatment process, convey the process material as dried heat treatment output material (30.1) out of the heat treatment chamber (14.1); a.2) A pyrolysis apparatus (12.2) for pyrolyzing materials, comprising: a.2-1) A shell (16.2) in which a process chamber is disposed, the process chamber defining a pyrolysis chamber (14.2). a.2-2) Pyrolysis atmosphere apparatus (22.2), which enables the generation of a pyrolysis atmosphere with a pyrolysis temperature, particularly between 100°C and 1000°C, in the pyrolysis chamber (14.2); a.2-3) Pyrolysis conveying device (28.2), which can convey the process material as the pyrolysis input material (26.2) to the pyrolysis chamber (14.2) and after the pyrolysis process, convey the process material as the pyrolysis output material (30.1) from the pyrolysis chamber (14.2); a.3) An activation apparatus (12.3) for activating materials, comprising: a.3-1) A housing (16.3) in which a process chamber is disposed, the process chamber defining an activation chamber (14.3). a.3-2) Activation atmosphere device (22.3), which enables the generation of an activation atmosphere having an activation temperature, particularly between 500°C and 1200°C, in the activation chamber (14.3); a.3-3) Activation conveying device (28.3): The activation conveying device can convey the process material as the activation input material (26.3) to be activated into the activation chamber (14.3), and after the activation process, the process material is conveyed out of the activation chamber (14.3) as the activated output material (30.3). in The preceding process chamber (34) and the subsequent process chamber (36) are formed by the heat treatment chamber (12.1) and the pyrolysis chamber (12.2), or by the pyrolysis chamber (12.2) and the activation chamber (12.3). and / or b) The furnace facility provides a permeation furnace system (40) for heat treatment and / or thermochemical treatment of materials, the permeation furnace system comprising at least two of the following process units (12.i): b.1) A temperature control device (12.4) for heating materials, comprising: b.1-1) A housing (16.4) in which a process chamber is disposed, the process chamber defining a temperature control chamber (14.4). b.1-2) Temperature regulating atmosphere device (22.4), which can generate a temperature regulating atmosphere (18.4) with a temperature regulating temperature, especially between 30°C and 600°C, in the temperature regulating room (14.4). b.1-3) Temperature regulating conveying device (28.4), which can convey process material as temperature regulating input material (26.4) to be heated into temperature regulating chamber (14.4), and after the temperature regulating process, convey the process material as heated temperature regulating output material (30.4) out of temperature regulating chamber (14.4); b.2) A permeation apparatus (12.5) for permeating a substrate into a material, comprising: b.2-1) A housing (16.5) in which a process chamber is disposed, the process chamber defining a permeation chamber (14.5). b.2-2) Permeation atmosphere device (22.5), which enables the generation of a permeation atmosphere (18.5) having a permeation temperature, particularly between 300°C and 600°C, in the permeation chamber (14.5). b.2-3) Permeation delivery device (28.5), which can deliver the process material as the permeation input material (26.5) to the permeation chamber (14.5) and after the permeation process, deliver the process material as the permeated permeation output material (30.5) out of the permeation chamber (14.5); b.3) A passivation apparatus (12.6, 12.8) for passivating materials, comprising: b.3-1) Housing (16.6, 16.8), in which a process chamber is disposed, the process chamber defining a passivation chamber (14.6, 14.8). b.3-2) Passivation atmosphere apparatus (22.6, 22.8), which enables the generation of a passivation atmosphere (18.6, 18.8) with a passivation temperature in the passivation chamber (14.6, 14.8). b.3-3) Passivation conveying device (28.6, 28.8): The passivation conveying device can convey the process material as the activation input material (26.6, 26.8) to the passivation chamber (14.6, 14.8), and after the passivation process, the process material is conveyed out of the passivation chamber (14.6, 14.8) as the passivated output material (30.6, 30.8); b.4) A cooling device (12.7) for cooling materials, comprising: b.4-1) A housing (16.7) in which a process chamber (14.7) is disposed, the process chamber defining a cooling chamber; b.4-2) Cooling atmosphere device (22.7), which enables the generation of a cooling atmosphere (18.7) having a cooling temperature, particularly between 600°C and 30°C, in the cooling chamber (14.7). b.4-3) Cooling conveying device (28.7), which is used to convey process materials as cooling input materials (26.7) to the cooling chamber (14.7), and after the cooling process, convey the process materials as cooled output materials (30.7) out of the cooling chamber (14.7). in The preceding process chamber (34) and the subsequent process chamber (36) are formed by the conditioning chamber (14.4) and the permeation chamber (14.5), or by the permeation chamber (14.5) and the passivation chamber (14.6), or by the passivation chamber (14.6) and the cooling chamber (14.7), or by the cooling chamber (14.7) and the passivation chamber (14.8).

3. The furnace facility according to claim 2, characterized in that, a) The activation furnace system (38) is provided, and in the activation furnace system (38), one, more or all airlock devices (32.i) located between the upstream process chamber (34) and its downstream process chamber (36) are designed as single-chamber airlocks; and / or b) The permeation furnace system (40) is provided, and in the permeation furnace system (40), one, more or all airlock devices (32.i) located between the upstream process chamber (34) and its downstream process chamber (36) are designed as dual-chamber airlocks.

4. The furnace facility according to claim 2 or 3, characterized in that, a) The activation furnace system (38) is provided such that the heat treatment chamber (14.1) forms a first upstream process chamber (34), the pyrolysis chamber (14.2) forms a first downstream process chamber (36) and a second upstream process chamber (34), and the activation chamber (14.3) forms a second downstream process chamber (36). and / or b) The permeation furnace system (40) is provided such that the conditioning chamber (14.4) forms a first upstream process chamber (34), the permeation chamber (14.5) forms a first downstream process chamber (36) and a second upstream process chamber (34), and b1) The passivation chamber (14.6) forms or is capable of forming a second subsequent process chamber (36) and a third front-end process chamber (34), and the cooling chamber (14.7) forms or is capable of forming a third subsequent process chamber (36). or b2) The cooling chamber (14.7) forms or is capable of forming a second subsequent process chamber (36) and a third preceding process chamber (34), and the passivation chamber (14.8) forms or is capable of forming a third subsequent process chamber (36).

5. The furnace installation according to claim 4, characterized in that The permeation furnace system (40) is provided such that it includes a first passivation chamber (14.6) and a second passivation chamber (14.8), wherein the first passivation chamber (14.6) is connected to the cooling chamber (14.7) via an airlock device (32.6), and the cooling chamber (14.7) is connected to the second passivation chamber (14.8) via an airlock device (32.7).

6. The furnace facility according to any one of claims 2 to 5, characterized in that, The activation furnace system (38) is provided such that multiple process zones are defined in the activation chamber (14.3) along the transport direction, in which different temperatures are generated and maintained.

7. The furnace facility according to claim 6, characterized in that, The process area of ​​the activation chamber (14.3) includes an activation zone (56) and one or more cooling zones (58), wherein the activation temperature is present in the activation zone and a temperature lower than the activation temperature is present in the cooling zone.

8. The furnace facility according to any one of claims 2 to 7, characterized in that, In the presence of the corresponding process equipment (12.i), a) The heat treatment atmosphere apparatus (22.1) provides an inert gas atmosphere, especially an atmosphere composed of nitrogen (N2), as the heat treatment atmosphere (18.1). and / or b) The pyrolysis atmosphere apparatus (22.2) provides an inert gas atmosphere, especially an atmosphere composed of nitrogen (N2), as the pyrolysis atmosphere (18.2). and / or c) The activating atmosphere device (22.3) is or contains oxygen compounds as the activating atmosphere (18.3); and / or d) The temperature control atmosphere device (22.4) provides an inert gas atmosphere, especially an atmosphere composed of nitrogen (N2), as the temperature control atmosphere (18.4). and / or e) The permeation atmosphere apparatus (22.5) provides an atmosphere as the permeation atmosphere (18.5) such that the atmosphere itself provides silicon or silicon compound as the permeation substrate; and / or f) The passivation atmosphere apparatus (22.6, 22.8) provides a passivation atmosphere (18.6) that contains or is a hydrocarbon and has a passivation temperature between 300°C and 600°C, or provides a passivation atmosphere (18.8) that contains or is air or a nitrogen / air mixture and has a passivation temperature between 30°C and 150°C as the passivation atmosphere (18.6, 18.8). and / or g) The cooling atmosphere device (22.7) provides nitrogen (N2) as the cooling atmosphere (18.7).

9. A method for manufacturing battery materials in a furnace facility, wherein, in a plurality of process units (12.i), the corresponding process materials are subjected to heat treatment and / or thermochemical treatment during processing, characterized in that, Use the furnace facility according to any one of claims 1 to 8.

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