Lithium oxide materials and methods for producing lithium oxide materials

Abstract

Embodiments disclosed herein are directed to lithium oxide systems, methods, and compositions. In various embodiments of the present disclosure, the systems, methods, and compositions are directed to micron-sized lithium oxide particles that are optimally dense and spherical for use in lithium battery applications.

Description

[Technical Field]

[0001] Incorporation by reference of any priority application This application claims the benefit of priority under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 63 / 487,218, filed February 27, 2023, the entire disclosure of which is incorporated herein by reference in its entirety.

[0002] The present disclosure is generally directed to lithium oxide compositions and methods for producing the same. [Background technology]

[0003] Lithium batteries have a high energy density, 1.5 to 2 times higher than that of Ni / Cd batteries when compared at the same capacity. Therefore, lithium batteries are widely used as power sources for mobile phones, laptops, electric vehicles, and similar devices. Because lithium batteries, as a major component, determine the performance of portable products, the need for high-performance batteries has emerged. Battery performance is required in various aspects, including high efficiency, stability at high temperatures, cycle life, and charge / discharge characteristics.

[0004] In lithium-ion batteries, lithium cobalt oxide is traditionally used as the cathode material. However, many alternative material systems have been developed and used. Generally, lithium and oxygen are essential parts of the material system.

[0005] Lithium oxide can be produced as a solid powder for use as an electrolyte in solid-state lithium batteries or as a cathode material for lithium-ion power batteries. The powder's microstructure, morphology, particle size, and the degree and type of possible contamination play a decisive role in selecting a powder suitable for use as a battery material in lithium batteries. These properties affect the electrochemical properties of the battery. Energy density, in particular, is of great importance. For example, energy density can affect the range an electric vehicle can travel and is influenced by the microstructural parameters mentioned above.

[0006] Therefore, there is a need for new processes to produce lithium oxide materials with optimal particle size and density. Summary of the Invention

[0007] For purposes of this Summary, certain aspects, advantages, and novel features of the invention are described herein. It should be understood that such advantages may not necessarily be achieved in accordance with any particular embodiment of the invention. Thus, for example, one skilled in the art will recognize that the invention may be embodied or practiced in a manner that achieves one advantage or advantages taught herein, but may not necessarily achieve other advantages that may be taught or suggested herein.

[0008] Some embodiments herein are directed to a process for producing lithium oxide particles, the process comprising: introducing one or more lithium-containing precursor powder materials into a microwave-generated plasma; contacting the one or more lithium precursor powder materials with the microwave-generated plasma; cooling and solidifying the lithium precursor to form one or more spherical lithium oxide particles; and recovering the one or more spherical lithium oxide particles, wherein the one or more spherical lithium oxide particles have an average particle size of less than about 500 μm.

[0009] In some embodiments, the one or more spherical lithium oxide particles have an average particle size between about 5 and 500 μm. In some embodiments, the one or more spherical lithium oxide particles have a D50 particle size between about 5 and 50 μm. In some embodiments, the one or more spherical lithium oxide particles have a D50 particle size between about 5 and 15 μm.

[0010] In some embodiments, the median sphericity of one or more of the spherical lithium oxide particles is greater than 0.5. In some embodiments, the median sphericity of one or more of the spherical lithium oxide particles is greater than 0.8. In some embodiments, the median sphericity of one or more of the spherical lithium oxide particles is greater than 0.95.

[0011] In some embodiments, the bulk average purity of the one or more spherical lithium oxide particles is at least about 20%, at least about 25%, at least about 40%, at least about 60%, at least about 80%, or at least about 95%. In some embodiments, the bulk average purity of the one or more spherical lithium oxide particles is at least 99%.

[0012] In some embodiments, the one or more spherical lithium oxide particles have an apparent density of at least 1.0 g / cm 3 In some embodiments, the apparent density of the one or more spherical lithium oxide particles is at least 2.5 g / cm 3 In some embodiments, the one or more spherical lithium oxide particles have an average particle size of less than about 250 μm. In some embodiments, the one or more spherical lithium oxide particles have an average particle size of less than about 100 μm. In some embodiments, the method further includes forming the one or more lithium oxide particles into a lithium-ion battery active material.

[0013] Some embodiments herein are directed to a lithium oxide powder comprising one or more lithium oxide (LiO) particles, wherein at least 50% of the lithium oxide particles have a sphericity greater than 0.75, and the lithium oxide particles have an average particle size of less than about 500 μm.

[0014] In some embodiments, the lithium oxide particles have an average particle size of less than about 250 μm. In some embodiments, the lithium oxide particles have an average particle size of less than about 100 μm. In some embodiments, the apparent density of the one or more lithium oxide particles is at least 1.5 g / cm. 3 In some embodiments, at least 50%, at least 75%, or at least 90% of the lithium oxide particles have a sphericity greater than 0.9. In some embodiments, at least 50%, at least 75%, or at least 90% of the lithium oxide particles have a sphericity greater than 0.95. In some embodiments, the apparent density of one or more lithium oxide particles is at least 2.5 g / cm. 3 In some embodiments, the bulk average purity of the one or more lithium oxide particles is at least about 20%, at least about 25%, at least about 40%, at least about 60%, at least about 80%, or at least about 95%. In some embodiments, the one or more lithium oxide particles have a D50 of about 5-15 μm. In some embodiments, at least 90% to about 99.9% of the lithium oxide particles comprise standalone particles.

[0015] The drawings are provided to illustrate exemplary embodiments and are not intended to limit the scope of the present disclosure. A better understanding of the systems and methods described herein will be appreciated by reference to the following description in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0016] [Figure 1]FIG. 1 illustrates an exemplary microwave plasma torch that may be used in the production of materials according to some embodiments herein. [Figure 2A] FIG. 2A illustrates an exemplary microwave plasma torch including a side-fed hopper, according to some embodiments herein. [Figure 2B] FIG. 2B illustrates an exemplary microwave plasma torch including a side-fed hopper, according to some embodiments herein. [Figure 3] FIG. 3 shows an SEM image of LiO 2 particles produced according to some embodiments herein. [Figure 4] FIG. 4 shows the mass uptake of particles after CO 2 exposure following conversion of the particles to LiO 2 , according to some embodiments herein. DETAILED DESCRIPTION OF THE INVENTION

[0017] Although certain preferred embodiments and examples are disclosed below, the inventive subject matter extends beyond the specifically disclosed embodiments to other alternative embodiments and / or uses, as well as modifications and equivalents thereof. Accordingly, the claims appended hereto are not limited by any of the specific embodiments described below. For example, in any method or process disclosed herein, the acts or operations of the method or process may be performed in any suitable order and are not necessarily limited to any particular disclosed sequence. Various operations may be described sequentially as multiple distinct operations in a manner that may aid in understanding particular embodiments, but the order of description should not be construed as implying that these operations are order-dependent. In addition, the structures, systems, and / or devices described herein may be embodied as integrated components or as separate components. For purposes of comparing various embodiments, certain aspects and advantages of these embodiments are described. Not all such aspects or advantages are necessarily realized by any particular embodiment. Thus, for example, various embodiments may be implemented in a manner that achieves or optimizes one advantage or advantages taught herein, but does not necessarily achieve other aspects or advantages that may be taught or suggested herein.

[0018] Certain exemplary embodiments are described herein to provide a thorough understanding of the principles of the structure, function, manufacture, and use of the devices and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments, and that the scope of the present invention is defined solely by the claims. Features shown or described in connection with one exemplary embodiment may be combined with features of other embodiments. Such modifications and variations are intended to be within the scope of the present technology.

[0019] Lithium oxide powder particles Some embodiments herein relate to the use of microwave plasma processing to produce submicron-sized lithium oxide particles. The lithium oxide particles can be optimally dense and spherical, allowing the lithium oxide particles to be utilized in a wide range of applications, such as electrolytes in all-solid-state lithium batteries or cathode materials for lithium-ion power batteries. The production of lithium oxide particles according to some embodiments herein enables energy-efficient, cost-effective, and environmentally sustainable battery storage capacity with a low carbon footprint. Furthermore, the lithium oxide particles can be produced in a matter of seconds through gas-phase or in-flight exposure to microwave plasma generated in a microwave plasma device, enabling more rapid production and scalability.

[0020] According to various embodiments herein, lithium oxide particles can be produced by exposure to microwave plasma rather than by solvent gelation. Furthermore, lithium oxide particles can be produced such that they do not require additional calcination or purification after solidification in a microwave plasma device. Finally, embodiments herein enable the production of lithium oxide particles that are substantially non-porous and have optimal density. The plasma device generates and provides a high-temperature, deflected stream of plasma for various purposes. Two major types of plasma torches are induction plasma torches and microwave plasma torches. In general, induction plasma suffers from plasma non-uniformity, which limits the ability of induction plasma to process certain materials. Furthermore, there are significant differences between microwave plasma systems and other plasma-generating torches, such as induction plasma. For example, microwave plasma has a higher temperature inside the plasma plume, while induction plasma has a higher temperature outside the plume. In particular, the outer region of induction plasma can reach approximately 7269°C (approximately 10,000K), while the inner processing region can only reach approximately 727°C (approximately 1,000K). This large temperature difference leads to material processing and feeding problems. Furthermore, induction plasma systems cannot process feedstocks at temperatures low enough to avoid melting certain feed materials without extinguishing the plasma. Therefore, in some embodiments, microwave plasma is used to process lithium oxide particles. In some embodiments, the purity of the lithium oxide particles can be at least about 95%. In some embodiments, the purity of the lithium oxide particles, defined as mol% LiO, is at least about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, or It can be about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, or any value between the aforementioned values.

[0021] microwave plasma device FIG. 1 illustrates an embodiment of a microwave plasma torch 100 that may be used in the production of materials according to some embodiments herein. In some embodiments, feedstock may be introduced into the microwave plasma 104 via one or more feedstock inlets 102. In some embodiments, an entrained airflow and / or sheath flow may be injected into the microwave plasma torch 100 to create flow conditions within the plasma torch prior to ignition of the plasma 104 via a microwave source 106. In some embodiments, the entrained flow and sheath flow are both axisymmetric and laminar, while in other embodiments, the airflow is swirling. In some embodiments, feedstock may be introduced into the microwave plasma torch 100, where it may be entrained by an airflow that directs the material into the plasma 104.

[0022] As previously discussed, the gas stream may include a noble gas from the periodic table, such as helium, neon, or argon. While the gases previously described may be used, it should be understood that a variety of gases may be used depending on the desired material and processing conditions. In some embodiments, within the microwave plasma 104, the feedstock may undergo physical and / or chemical transformations. The inlet 102 may be used to introduce a process gas to entrain and accelerate the feedstock toward the plasma 104. In some embodiments, a second gas stream may be generated to provide sheathing to the inner walls of the core gas tube 108 and reaction chamber 110 to prevent melting of those structures due to thermal radiation from the plasma 104.

[0023] Various parameters of the microwave plasma 104 may be adjusted manually or automatically to achieve the desired material, including, for example, power, plasma gas flow rate, plasma gas type, presence of extension tubes, extension tube material, reactor chamber or extension tube insulation level, extension tube coating level, extension tube geometry (e.g., tapered, These may include (stepwise / staged), feed size, feed insertion rate, feed inlet location, feed inlet arrangement, number of feed inlets, plasma temperature, residence time, and cooling rate. The resulting material exits the plasma into the sealed chamber 112 where it is quenched and can then be collected.

[0024] In some embodiments, the feedstock material is injected after the microwave plasma torch applicator for processing in the microwave plasma torch "plume" or "exhaust." Thus, the microwave plasma torch plasma engages at the exit end of the plasma torch core tube 108 or further downstream. In some embodiments, an adjustable downstream feed allows the feedstock material to engage with the downstream plasma plume at a temperature suitable for optimal melting of the feedstock material by precisely targeting the temperature level and residence time. Adjusting the inlet location and plasma characteristics may allow further tailoring of material properties. Furthermore, in some embodiments, the length of the plasma plume can be adjusted by adjusting the power, gas flow rate, pressure, and tool configuration (e.g., by introducing an extension tube).

[0025] In some embodiments, the feed configuration may include one or more individual feed nozzles surrounding the plasma plume. The feedstock may enter the plasma from any direction and may be fed 360° around the plasma, depending on the location and arrangement of the inlets 102. Moreover, the feedstock may enter the plasma at specific locations along the length of the plasma 104 by adjusting the location of the inlets 102, where specific temperatures have been measured and residence times estimated to provide desired properties of the resulting material.

[0026] In some embodiments, the angle of the inlet 102 relative to the plasma 104 can be adjusted so that the feedstock can be injected at any angle relative to the plasma 104. For example, the inlet 102 can be adjusted so that the feedstock can be injected into the plasma at an angle of about 0°, about 5°, about 10°, about 15°, about 20°, about 25°, about 30°, about 35°, about 40°, about 45°, about 50°, about 55°, about 60°, about 65°, about 70°, about 75°, about 80°, about 85°, or about 90° relative to the direction of the plasma 104, or any angle between the aforementioned values.

[0027] In some embodiments, downstream injection implementations may utilize downstream swirling or quenching. Downstream swirling refers to an additional swirling component that may be introduced downstream from the plasma torch to prevent the powder from adhering to the walls of the core tube 108, reactor chamber 110, and / or extension tube 114.

[0028] In some embodiments, the length of the reaction chamber 110 of the microwave plasma device is about 1 foot, about 2 feet, about 3 feet, about 4 feet, about 5 feet, about 6 feet, about 7 feet, about 8 feet, about 9 feet, about 10 feet, about 11 feet, about 12 feet, about 13 feet, about 14 feet, about 15 feet, about 16 feet, about 17 feet, about 18 feet, about 20 feet, about 21 feet, about 22 feet, about 24 feet, about 25 feet, about 26 feet, about 27 feet, about 28 feet, about 29 feet, about 30 feet, about 31 feet, about 32 feet, about 33 feet, about 34 feet, about 35 feet, about 36 feet, about 37 feet, about 38 feet, about 39 feet, about 40 feet, about 41 feet, about 42 feet, about 45 feet, about 46 feet, about 47 feet, about 48 feet, about 49 feet, about 50 feet, about 51 feet, about 52 feet, about 53 feet, about 54 feet, about 55 feet, about 56 feet, about 57 feet, about 58 feet, about 59 feet, about 60 feet, about 61 feet, about 62 feet, about 64 feet, about 65 feet, about 66 feet, about 67 feet, about 68 feet, about 69 feet, about 70 feet, about 71 feet, about 72 feet, about 73 feet, about 74 feet, about 75 feet, about 76 feet, about 77 feet, about 78 feet, about 79 feet, about 80 feet, about 81 feet, about 82 feet, about 83 feet, about 84 feet, about 85 feet, about 86 feet, about 87 feet, about 88 feet, about ), about 16 feet, about 17 feet, about 18 feet, about 19 feet, about 20 feet, about 21 feet, about 22 feet, about 23 feet, about 24 feet, about 25 feet, about 26 feet, about 27 feet, about 28 feet, about 29 feet, or about 30 feet, or any value between the aforementioned values.

[0029] In some embodiments, the length of the plasma 104 can be extended by adjusting various process conditions and equipment configurations to approximately 1 foot, 2 feet, 3 feet, 4 feet, 5 feet, 6 feet, 7 feet, 8 feet, 9 feet, 10 feet, 11 feet, 12 feet, 13 feet, 14 feet, 15 feet, 16 feet, 17 feet, 18 feet, 19 feet, 20 feet, 21 feet, 22 feet, 23 feet, 24 feet, 25 feet, 26 feet, 27 feet, 28 feet, 29 feet, 30 feet, 31 feet, 32 feet, 33 feet, 34 feet, 35 feet, 36 feet, 37 feet, 38 feet, 40 feet, 41 feet, 42 feet, 43 feet, 44 feet, 45 feet, 46 feet, 47 feet, 48 feet, 50 feet, 51 feet, 52 feet, 53 feet, 54 feet, 55 feet, 56 feet, 57 feet, 58 feet, 59 feet, 60 feet, 61 feet, 62 feet, 63 feet, 64 feet, 65 feet, 66 feet, 67 feet, 68 feet, 69 feet, 70 feet, 71 feet, 72 feet, 73 feet, 74 feet, 75 feet, 76 feet, 77 feet, 78 feet, 79 feet, 80 feet, 81 feet, 82 feet, 83 feet, 84 feet, 85 feet, 86 feet, 87 feet, 88 feet, 89 feet, 90 feet, 91 feet, 92 feet, 93 feet, 94 feet, 95 feet, 96 feet, 97 feet, 98 feet, 99 feet, 100 feet, 1 The length may be about 15 feet, about 16 feet, about 17 feet, about 18 feet, about 19 feet, about 20 feet, about 21 feet, about 22 feet, about 23 feet, about 24 feet, about 25 feet, about 26 feet, about 27 feet, about 28 feet, about 29 feet, or about 30 feet, or any value between the aforementioned values.

[0030] In some embodiments, both the entrainment flow and the sheath flow are axisymmetric and laminar, while in other embodiments, the gas flow is swirling. Feed material may be introduced axially into the microwave plasma torch, where it is entrained by the gas flow, which directs the material toward the plasma. Within the microwave-generated plasma, the feed material may be melted or partially melted to spheroidize the material. An inlet may be used to introduce a process gas to entrain and accelerate the particles toward the plasma. In some embodiments, the particles are accelerated by entrainment using a core laminar gas flow generated through an annular gap within the plasma torch. A second laminar flow may be generated through the second annular gap to provide laminar sheathing to the inner walls of the dielectric torch to prevent melting of the walls due to thermal radiation from the plasma. In some embodiments, the laminar flow directs the particles into the plasma along a path as close as possible to the central axis of the plasma, exposing the particles to a substantially uniform temperature within the plasma.

[0031] In some embodiments, appropriate flow conditions exist to prevent particles from reaching the inner walls of the plasma torch where plasma deposition can occur. In some embodiments, the particles are guided by an airflow toward the microwave plasma so that each particle undergoes a uniform heat treatment. Various parameters of the microwave-generated plasma as well as particle parameters may be adjusted to achieve the desired results. These parameters may include microwave power, feed size, feed insertion rate, gas flow rate, plasma temperature, residence time, and cooling rate. In some embodiments, the cooling or quenching rate is 10 s or less upon exiting the plasma. +3 °C / sec or greater. As discussed above, in some embodiments the gas flow is laminar, although in alternative embodiments swirl and turbulence may be used to direct the feed material into the plasma.

[0032] 2A-B show an exemplary microwave plasma torch that includes a side-feed hopper, thereby enabling downstream feeding. Thus, in this implementation, the feedstock is injected after the microwave plasma torch applicator for processing in the "plume" or "exhaust" of the microwave plasma torch. Thus, the microwave plasma torch plasma meets at the exit end of the plasma torch to enable downstream feeding of the feedstock. This downstream feeding can advantageously extend the life of the torch, since the high-temperature zone indefinitely prevents any material from adhering to the walls of the high-temperature zone liner. Furthermore, it allows the downstream plasma plume to meet at a temperature appropriate for optimal processing of the powder through precise targeting of temperature levels and residence times. For example, there is the ability to dial in plume length using microwave powder, airflow, and pressure within the quenching vessel containing the plasma plume.

[0033] Generally, downstream spheroidization methods can utilize two primary hardware configurations to establish a stable plasma plume: an annular torch, as described in U.S. Patent Application Publication No. 2018 / 0297122, or a swirling torch, as described in U.S. Patent Nos. 8,748,785 B2 and 9,932,673 B2, each of which is incorporated herein by reference in its entirety. A feeding system closely coupled to the plasma plume at the exit of the plasma torch is used to feed the powder axisymmetrically to maintain process uniformity.

[0034] Other feed configurations can include one or more individual feed nozzles surrounding the plasma plume. The feedstock powder can enter the plasma at a point from any direction and be fed to that point within the plasma from any direction around the plasma. The feedstock powder can enter the plasma at specific locations along the length of the plasma plume, where specific temperatures in the plasma plume are measured and residence times estimated for sufficient particle melting. The molten particles exit the plasma and enter a sealed chamber where they are quenched and then collected.

[0035] The feed material 214 may be introduced into the microwave plasma torch 202. A hopper 206 may be used to store the feed material 214 before delivering it into the microwave plasma torch 202, the plume, or the exhaust. The feed material 214 may be injected at any angle relative to the longitudinal direction of the plasma torch 202, such as 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55°, or any value between the aforementioned values. In some embodiments, the feed material may be injected at an angle greater than 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, or 55°. In some embodiments, the feed material may be injected at an angle less than 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, or 55°. In alternative embodiments, the feed material may be injected along the longitudinal axis of the plasma torch.

[0036] Microwave radiation may be delivered into the plasma torch through a waveguide 204. A feed material 214 may be fed into the plasma chamber 210 and positioned to contact the plasma generated by the plasma torch 202. The feed material may melt upon contact with the plasma, plasma plume, or plasma exhaust. The feed material 214 may cool and solidify while still in the plasma chamber 210 before being collected in the container 212. Alternatively, the feed material 214 may exit the plasma 210 in the molten phase and cool and solidify outside the plasma chamber. In some embodiments, a quenching chamber may be used, which may or may not utilize positive pressure. The embodiment of Figures 2A and 2B is described separately from Figure 1, but it is understood that it utilizes similar features and conditions as the embodiment of Figure 1. [Example]

[0037] Various experiments were performed to test the viability of lithium oxide materials produced according to embodiments herein. In some embodiments, a horizontal twin auger feeder may be used to direct a downward crossflow of one or more gases into a small diameter carrier tube. In some embodiments, the powder injection nozzle is fabricated from a 3 / 8 inch tube structure with an inner diameter of about 0.77 cm (about 0.305 inches) and a terminal inch of the tube structure flattened to create an internal gap of about 0.10 inches (about 0.25 cm). In some embodiments, the powder injection nozzle is positioned to avoid the hottest part of the plasma plume to avoid particle explosion issues. In some embodiments, the nozzle is positioned between about 0 cm (about 0 inches) and about 91 cm (about 36 inches) below the exit of the plasma torch. In some embodiments, the nozzle may be positioned below the outlet of the plasma torch at about 0.0 cm (about 0.0 inch), about 0.5 inch, about 1.0 inch, about 1.5 inch, about 2.0 inches, about 2.5 inches, about 3.0 inches, about 3.5 inches, about 4.0 inches, about 4.5 inches, about 5.0 inches, about 5.5 inches, about 6.0 inches, about 7.6 cm, about 8.9 cm, about 9.0 cm, about 10.2 cm, about 11.4 cm, about 12.7 cm, about 14.0 cm, about 15.2 cm, about 16.0 cm, about 17.0 cm, about 18.0 cm, about 19.0 cm, about 20.0 cm, about 21.0 cm, about 22.0 cm, about 23.0 cm, about 24.0 cm, about 25.0 cm, about 26.0 cm, about 27.0 cm, about 28.0 cm, about 29.0 cm, about 30.0 cm, about 31.0 cm, about 32.0 cm, about 33.0 cm, about 34.0 cm, about 35.0 cm, about 36.0 cm, about 37.0 cm, about 38.0 cm, about 39.0 cm, about 40.0 cm, about 41.0 cm, about 42.0 cm, about 43.0 cm, about 44.0 cm, about 45.0 cm, about 46.0 cm, about 47.0 cm, about 48.0 cm, about 49.0 cm, about 50.0 cm, about 51.0 cm, about 52.0 cm, about 53.0 cm, about 54.0 cm, about 55.0 cm, about 56.0 cm, about Approximately 16.5 cm (approximately 6.5 inches), approximately 17.8 cm (approximately 7.0 inches), approximately 19.1 cm (approximately 7.5 inches), approximately 20.3 cm (approximately 8.0 inches), approximately 21.6 cm (approximately 8.5 inches), approximately 22.9 cm (approximately 9.0 inches), approximately 24.1 cm (approximately 9.5 inches), approximately 25.4 cm (approximately 10.0 inches), approximately 26.7 cm (approximately 10.5 inches), approximately 27.9 cm (approximately 11.0 inches), approximately 29.2 cm (approximately 11.5 inches), approximately 30.5 cm (approximately 12.0 inches), approximately 31.8 cm (approximately 12.5 inches), approximately 33.0 cm (approximately 13.0 inches), approximately 34 0.3cm (approx. 13.5 inches), approx. 35.6cm (approx. 14.0 inches), approx. 36.8cm (approx. 14.5 inches), approx. 38.1cm (approx. 15.0 inches), approx. 39.4cm (approx. 15.5 inches), approx. 40.6cm (approx. 16.0 inches), approx. 41.9cm (approx. 16.5 inches), approx. 43.2cm (approx. 17.0 inches), approx. 44.5cm (approx. 17.5 inches), approx. 45.7cm (approx. 18.0 inches), approx. 47.0cm (approx. 18.5 inches), approx. 48.3cm (approx. 19.0 inches), approx. 49.5cm (approx. 19.5 inches), approx. 50.8cm (approx. 20.0 inches) ), approximately 52.1 cm (approximately 20.5 inches), approximately 53.3 cm (approximately 21.0 inches), approximately 54.6 cm (approximately 21.5 inches), approximately 55.8 cm (approximately 22.0 inches), approximately 57.2 cm (approximately 22.5 inches), approximately 58.4 cm (approximately 23.0 inches), approximately 59.7 cm (approximately 23.5 inches), approximately 61.0 cm (approximately 24.0 inches), approximately 62.2 cm (approximately 24.5 inches), approximately 63.5 cm (approximately 25.0 inches), approximately 55.9 cm (approximately 25.5 inches), approximately 66.0 cm (approximately 26.0 inches), approximately 67.3 cm (approximately 26.5 inches), approximately 68.6 cm (approximately 27.0 inches), approximately 69.9 cm (approximately 27.5 inches), approximately 71.1 cm (approximately 28.0 inches), approximately 72.4 cm (approximately 28.5 inches), approximately 73.7 cm (approximately 29.0 inches), approximately 74.9 cm (approximately 29.5 inches), approximately 76.2 cm (approximately 30.0 inches), approximately 77.5 cm (approximately 30.5 inches), approximately 78.7 cm (approximately 31.0 inches), approximately 80.0 cm (approximately 31.5 inches), approximately 81.3 cm (approximately 3 2.0 inches), about 32.5 inches, about 33.0 inches, about 33.5 inches, about 34.0 inches, about 34.5 inches, about 35.0 inches, about 35.5 inches, about 36.0 inches, or any value between the aforementioned values.

[0038] In some embodiments, one or more quench nozzles can be positioned between about 2.5 cm (about 1 inch) and about 305 cm (about 120 inches) below the feed pipe. In some embodiments, quenching the particles reduces particle residence time within a temperature range that promotes carbon dioxide reuptake. In some embodiments, the quench nozzle or nozzles are located about 1 inch (2.5 cm), about 2 inches (5.1 cm), about 3 inches (7.6 cm), about 4 inches (10.2 cm), about 5 inches (12.7 cm), about 6 inches (15.2 cm), about 7 inches (17.8 cm), about 8 inches (20.3 cm), about 9 inches (22.9 cm), about 10 inches (25.4 cm), about 11 inches (27.9 cm), about 12 inches (30.5 cm), about 13 inches (33.0 cm), about 35.6cm (approx. 14 inches), 38.1cm (approx. 15 inches), 40.6cm (approx. 16 inches), 43.2cm (approx. 17 inches), 45.7cm (approx. 18 inches), 48.3cm (approx. 19 inches), 50.8cm (approx. 20 inches), 53.3cm (approx. 21 inches), 55.9cm (approx. 22 inches), 58.4cm (approx. 23 inches), 70.0cm (approx. 24 inches), 63.5cm (approx. 25 inches), 66.0cm (approx. 26 inches), 68.6cm (approx. 27 inches), 71.1cm (approx.28 inches), approximately 73.7 cm (approximately 29 inches), approximately 76.2 cm (approximately 30 inches), approximately 78.7 cm (approximately 31 inches), approximately 81.3 cm (approximately 32 inches), approximately 83.8 cm (approximately 33 inches), approximately 86.4 cm (approximately 34 inches), approximately 88.9 cm (approximately 35 inches), approximately 91.4 cm (approximately 36 inches), approximately 94.0 cm (approximately 37 inches), approximately 96.5 cm (approximately 38 inches), approximately 99.1 cm (approximately 39 inches), approximately 101.6 cm (approximately 40 inches), approximately 104.1 cm (approximately 41 inches), approximately 106.7 cm (approximately 42 inches), approximately 109.2 cm (approximately 43 inches) inches), approximately 111.8 cm (approximately 44 inches), approximately 114.3 cm (approximately 45 inches), approximately 116.8 cm (approximately 46 inches), approximately 119.4 cm (approximately 47 inches), approximately 121.9 cm (approximately 48 inches), approximately 124.5 cm (approximately 49 inches), approximately 127 cm (approximately 50 inches), approximately 129.5 cm (approximately 51 inches), approximately 132.1 cm (approximately 52 inches), approximately 134.6 cm (approximately 53 inches), approximately 137.2 cm (approximately 54 inches), approximately 139.7 cm (approximately 55 inches), approximately 142.2 cm (approximately 56 inches), approximately 144.8 cm (approximately 57 inches), approximately 147. 149.9cm (approx. 59 inches), 152.4cm (approx. 60 inches), 154.9cm (approx. 61 inches), 157.5cm (approx. 62 inches), 160.0cm (approx. 63 inches), 162.6cm (approx. 64 inches), 165.1cm (approx. 65 inches), 167.6cm (approx. 66 inches), 170.2cm (approx. 67 inches), 172.7cm (approx. 68 inches), 175.3cm (approx. 69 inches), 177.8cm (approx. 70 inches), 180.3cm (approx. 71 inches), 182.3cm (approx. 72 inches) inches), approximately 185.4 cm (approximately 73 inches), approximately 188.0 cm (approximately 74 inches), approximately 190.5 cm (approximately 75 inches), approximately 193.0 cm (approximately 76 inches), approximately 195.6 cm (approximately 77 inches), approximately 198.1 cm (approximately 78 inches), approximately 200.7 cm (approximately 79 inches), approximately 203.2 cm (approximately 80 inches), approximately 205.7 cm (approximately 81 inches), approximately 208.3 cm (approximately 82 inches), approximately 210.8 cm (approximately 83 inches), approximately 213.4 cm (approximately 84 inches), approximately 215.9 cm (approximately 85 inches), approximately 218.4 cm (approximately 86 inches), approximately 221.0cm (approximately 87 inches), approximately 223.5cm (approximately 88 inches), approximately 226.1cm (approximately 89 inches), approximately 228.6cm (approximately 90 inches), approximately 231.1cm (approximately 91 inches), approximately 233.7cm (approximately 92 inches), approximately 236.2cm (approximately 93 inches), approximately 238.8cm (approximately 94 inches), approximately 241.3cm (approximately 95 inches), approximately 243. 8cm (approx. 96 inches), approx. 246.4cm (approx. 97 inches), approx. 248.9cm (approx. 98 inches), approx. 251.5cm (approx. 99 inches), approx. 254cm (approx. 100 inches), approx. 256.5cm (approx. 101 inches), approx. 259.1cm (approx. 102 inches), approx. 261.6cm (approx. 103 inches), approx. 264.2cm (approx. 104 inches), approx. 6.7cm (approx. 105 inches), approx. 269.2cm (approx. 106 inches), approx. 271.8cm (approx. 107 inches), approx. 274.3cm (approx. 108 inches), approx. 276.9cm (approx. 109 inches), approx. 279.4cm (approx. 110 inches), approx. 281.9cm (approx. 111 inches), approx. 284.5cm (approx. 112 inches), approx. 287.0cm (approx. 11 The distance may be about 113 inches, about 114 inches, about 115 inches, about 116 inches, about 117 inches, about 118 inches, about 119 inches, about 120 inches, or any distance between the aforementioned values.

[0039] In some embodiments, there may be one or more collection points after processing. In some embodiments, a first collection vessel (C1) is located directly below the reactor to collect larger particles. In some embodiments, a second collection vessel (CY1) is located below a 1-inch feed cyclone to collect target particle sizes. In some embodiments, a third collection vessel (BH1) is located below the baghouse to collect smaller particles. Table 1 contains exemplary conversion and yield results for testing according to some embodiments herein. [Table 1]

[0040] In some embodiments, the rate of the lithium carbonate feed can be about 0.22 kg / hr. In some embodiments, the rate of the lithium carbonate feed can be about 0.01 kg / hr to about 1.00 kg / hr. In some embodiments, the rate of the lithium carbonate feed can be about 0.01 kg / hr, about 0.02 kg / hr, about 0.03 kg / hr, about 0.04 kg / hr, about 0.05 kg / hr, about 0.06 kg / hr, about 0.07 kg / hr, about 0.08 kg / hr, about 0.09 kg / hr, about 0.10 kg / hr, about 0.11 kg / hr, about 0.12 kg / hr, about 0.13 kg / hr, about 0.14 kg / hr, about 0.15 kg / hr, about 0.16 kg / hr, about 0.17 kg / hr, about 0.18 kg / hr, About 0.19 kg / hour, about 0.20 kg / hour, about 0.21 kg / hour, about 0.22 kg / hour, about 0.23 kg / hour, about 0.24 kg / hour, about 0.25 kg / hour, about 0.26 kg / hour, about 0.27 kg / hour, about 0.28 kg / hour, about 0.29 kg / hour, about 0.30 kg / hour, about 0.31 kg / hour, about 0.32 kg / hour, about 0.33 kg / hour, about 0.34 kg / hour, about 0.35 kg / hour, about 0.36 kg / hour, about 0.37 kg / hour, about 0.38 kg / hour, about 0.39 kg / hour, about 0.40 kg / hour, about 0.41 kg / hour, about 0.42 kg / hour, about 0.43 kg / hour, about 0.44 kg / hour, about 0.45 kg / hour, about 0.46 kg / hour, about 0.47 kg / hour, about 0.48 kg / hour, about 0.49 kg / hour, about 0.50 kg / hour, about 0.51 kg / hour, about 0.52 kg / hour, about 0.53 kg / hour, about 0.54 kg / hour, about 0.55 kg / hour, about 0.56 kg / hour, about 0.57 kg / hour, about 0.58 kg / hour, about 0.59 kg / hour Between, approximately 0.60 kg / hour, approximately 0.61 kg / hour, approximately 0.62 kg / hour, approximately 0.63 kg / hour, approximately 0.64 kg / hour, approximately 0.65 kg / hour, approximately 0.66 kg / hour, approximately 0.67 kg / hour, approximately 0.68 kg / hour, approximately 0.69 kg / hour, approximately 0.70 kg / hour, approximately 0.71 kg / hour, approximately 0.72 kg / hour, approximately 0.73 kg / hour, approximately 0.74 kg / hour, approximately 0.75 kg / hour, approximately 0.76 kg / hour, approximately 0.77 kg / hour, approximately 0.78 kg / hour, approximately 0.79 kg / hour, approximately 0.The rate may be about 80 kg / hr, about 0.81 kg / hr, about 0.82 kg / hr, about 0.83 kg / hr, about 0.84 kg / hr, about 0.85 kg / hr, about 0.86 kg / hr, about 0.87 kg / hr, about 0.88 kg / hr, about 0.89 kg / hr, about 0.90 kg / hr, about 0.91 kg / hr, about 0.92 kg / hr, about 0.93 kg / hr, about 0.94 kg / hr, about 0.95 kg / hr, about 0.96 kg / hr, about 0.97 kg / hr, about 0.98 kg / hr, about 0.99 kg / hr, about 1.00 kg / hr, or any value between the aforementioned values.

[0041] In some embodiments, the core plasma gas may be injected at a flow rate of about 175 slpm. In some embodiments, the plasma gas may include nitrogen gas. In some embodiments, the core plasma gas may be injected at a flow rate between about 10 slpm and about 400 slpm. In some embodiments, the core plasma gas may be injected at a flow rate between about 10 slpm, about 15 slpm, about 20 slpm, about 25 slpm, about 30 slpm, about 35 slpm, about 40 slpm, about 45 slpm, about 50 slpm, about 55 slpm, about 60 slpm, about 65 slpm, about 70 slpm, about 75 slpm, about 80 slpm, about 85 slpm, about 90 slpm, about 95 slpm, about 100 slpm, about 105 slpm, about 110 slpm, Approximately 115slpm, approximately 120slpm, approximately 125slpm, approximately 130slpm, approximately 135slpm, approximately 140slpm, approximately 145slpm, approximately 150slpm, approximately 155slpm, approximately 160slpm, approximately 165slpm, approximately 170slpm, approximately 175slpm, approximately 180slpm, approximately 185slpm, approximately 190slpm, approximately 195slpm, approximately 200slpm, approximately 205slpm, approximately 210slpm, approximately 215slpm, approximately 220slpm, approximately 225slpm, approximately 230slpm, approximately 235slpm, approximately 240slpm, approximately 245slpm, approximately 250slpm, approximately 255slpm, approximately 260slpm, approximately 26 The fluid may be injected at a flow rate of 5 slpm, about 270 slpm, about 275 slpm, about 280 slpm, about 285 slpm, about 290 slpm, about 295 slpm, about 300 slpm, about 305 slpm, about 310 slpm, about 315 slpm, about 320 slpm, about 325 slpm, about 330 slpm, about 335 slpm, about 340 slpm, about 345 slpm, about 350 slpm, about 355 slpm, about 360 slpm, about 365 slpm, about 370 slpm, about 375 slpm, about 380 slpm, about 385 slpm, about 390 slpm, about 395 slpm, about 400 slpm, or any value between the aforementioned values.

[0042] In some embodiments, the swirling plasma gas may be injected at a flow rate of about 35 slpm. In some embodiments, the swirling plasma gas may include nitrogen gas. In some embodiments, the swirling plasma gas may be injected at a flow rate between about 5 slpm and about 100 slpm. In some embodiments, the swirling plasma gas may be injected at a flow rate of about 5 slpm, about 10 slpm, about 15 slpm, about 20 slpm, about 25 slpm, about 30 slpm, about 35 slpm, about 40 slpm, about 45 slpm, about 50 slpm, about 55 slpm, about 60 slpm, about 65 slpm, about 70 slpm, about 75 slpm, about 80 slpm, about 85 slpm, about 90 slpm, about 95 slpm, or about 100 slpm.

[0043] In some embodiments, the plasma torch can be activated at about 18 kW power and then adjusted to maintain an exit temperature of about 740° C. In some embodiments, the plasma torch power can be maintained between about 1 kW and about 50 kW. In some embodiments, the plasma torch power can be maintained at about 1 kW, about 2 kW, about 3 kW, about 4 kW, about 5 kW, about 6 kW, about 7 kW, about 8 kW, about 9 kW, about 10 kW, about 11 kW, about 12 kW, about 13 kW, about 14 kW, about 15 kW, about 16 kW, about 17 kW, about 18 kW, about 19 kW, about 20 kW, about 21 kW, about 22 kW, about 23 kW, about 24 kW, about 25 kW, about 26 kW, about 27 kW, about 28 kW, about 29 kW, about 30 kW, about 31 kW, about 32 kW, about 33 kW, about 34 kW, about 35 kW, about 36 kW, about 37 kW, about 38 kW, about 39 kW, about 40 kW, about 41 kW, about 42 kW, about 43 kW, about 44 kW, about 45 kW, about 46 kW, about 47 kW, about 48 kW, about 49 kW, about 50 kW, about 51 kW, about 52 kW, about 53 kW, about 54 kW, about 55 kW, about 56 kW, about 57 kW, about 58 kW, about 59 kW, about 60 kW, about 61 kW, about 62 kW, about 63 kW, about kw, about 27 kw, about 28 kw, about 29 kw, about 30 kw, about 31 kw, about 32 kw, about 33 kw, about 34 kw, about 35 kw, about 36 kw, about 37 kw, about 38 kw, about 39 kw, about 40 kw, about 41 kw, about 42 kw, about 43 kw, about 44 kw, about 45 kw, about 46 kw, about 47 kw, about 48 kw, about 49 kw, about 50 kw, or any value between the aforementioned values.

[0044] In some embodiments, the waveguide gas may be injected at a flow rate of about 30 slpm. In some embodiments, the waveguide gas may include nitrogen gas. In some embodiments, the waveguide gas may be injected at a flow rate between about 5 slpm and about 100 slpm. In some embodiments, the waveguide gas may be injected at a flow rate of about 5 slpm, about 10 slpm, about 15 slpm, about 20 slpm, about 25 slpm, about 30 slpm, about 35 slpm, about 40 slpm, about 45 slpm, about 50 slpm, about 55 slpm, about 60 slpm, about 65 slpm, about 70 slpm, about 75 slpm, about 80 slpm, about 85 slpm, about 90 slpm, about 95 slpm, or about 100 slpm.

[0045] In some embodiments, the quench gas may be injected at a flow rate of about 280 slpm. In some embodiments, the quench gas may include nitrogen gas. In some embodiments, the quench gas may be injected at a flow rate between about 5 slpm and about 400 slpm. In some embodiments, the waveguide gas may be injected at a flow rate between about 5 slpm, about 10 slpm, about 15 slpm, about 20 slpm, about 25 slpm, about 30 slpm, about 35 slpm, about 40 slpm, about 45 slpm, about 50 slpm, about 55 slpm, about 60 slpm, about 65 slpm, about 70 slpm, about 75 slpm, about 80 slpm, about 85 slpm, about 90 slpm, about 95 slpm, about 100 slpm, about 105 slpm, or about 110 slpm. pm, about 110slpm, about 115slpm, about 120slpm, about 125slpm, about 130slpm, about 135slpm, about 140slpm, about 145slpm, about 150slpm, about 155slpm, Approximately 160slpm, approximately 165slpm, approximately 170slpm, approximately 175slpm, approximately 180slpm, approximately 185slpm, approximately 190slpm, approximately 195slpm, approximately 200slpm, approximately 205slpm, approximately 21 0slpm, approx. 215slpm, approx. 220slpm, approx. 225slpm, approx. 230slpm, approx. 235slpm, approx. 240slpm, approx. 245slpm, approx. 250slpm, approx. 255slpm, approx. 260slpm, approx. 265slpm, approx. 270slpm, approx. 275slpm, approx. 280slpm, approx. 285slpm, approx. 290slpm, approx. 295slpm, approx. 300slpm, approx. 305slpm, approx. 310slpm, It may be injected at a flow rate of about 315 slpm, about 320 slpm, about 325 slpm, about 330 slpm, about 335 slpm, about 340 slpm, about 345 slpm, about 350 slpm, about 355 slpm, about 360 slpm, about 365 slpm, about 370 slpm, about 375 slpm, about 380 slpm, about 385 slpm, about 390 slpm, about 395 slpm, about 400 slpm, or any value between the aforementioned values.

[0046] FIG. 3 shows an SEM image of LiO particles produced according to embodiments of the present disclosure. The SEM image of the LiO particles has a dimension of 2 μm (bottom left), was produced at an electron high tension (EHT) of 10 kilovolts (kV), and had a working distance (WD) of 6.56 mm. As shown in the image, the lithium oxide particles can be substantially or completely monolithic, such that each particle is separated from the others (i.e., not fused to one another). The vast majority of the particles in the image are spherical in shape and are not attached to or fused to other spherical lithium oxide particles. In some embodiments, the lithium oxide particles produced and imaged have a diameter of less than 100 μmin and optimal sphericity, since the vast majority of the particles are present as monolithic particles and have optimal spherical curvature.

[0047] Single particle Various embodiments of the present disclosure may describe lithium oxide particles as "single-type" particles. As used herein, "single-type" particles may be interpreted as a sampling of particles in which at least 60% of the particles are not fused to other particles. "Single-type" lithium oxide particles according to embodiments herein may include particles in which at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, at least 97%, or at least 99%, or at least 99.9% of the particles are not fused to other particles. In some embodiments, nanosized satellites may be observed on the surface of the particles resulting from LiO condensation during the microwave plasma process. Thus, "single-type" particles include those in which there are no two fused particles with a radius ratio of each particle within 10:1 to 1:10. In some embodiments, if a particle has a radius greater than 10 times the radius of the satellite, the particle may still be considered a "single-type" particle.

[0048] Embodiments herein provide superior results to prior art processes, in that microwave plasma processes provide a cost-effective and energy-efficient process for producing lithium oxide particles. For example, in-flight solidification of lithium oxide particles in a microwave plasma device allows for the production of monolithic particles that are optimally dense and spherical. The spherical lithium oxide particles can be further used and incorporated in batteries and other energy storage devices, with or without the incorporation of additional elements within or on the lithium oxide particles.

[0049] Microwave Plasma Processing In microwave plasma processes, feedstock materials can be entrained in an inert and / or reducing gas environment and injected into the microwave plasma, microwave plasma plume, or microwave plasma exhaust. Injection into the high-temperature plasma (or plasma plume or exhaust) can cause the feedstock materials to undergo physical and / or chemical transformations (e.g., spheroidization). After processing, the resulting material can be released into a chamber filled with an inert gas and directed into a sealed drum for storage. This process can be carried out at atmospheric pressure, a partial vacuum, or slightly above atmospheric pressure.

[0050] In alternative embodiments, the process can be carried out in low, medium, or high vacuum environments. The process can be carried out batchwise or continuously, and drums can be replaced when filled with processed material. By controlling process parameters such as cooling gas flow rate, residence time, plasma conditions, and cooling gas composition, various material properties can be controlled.

[0051] The residence time of the particles within the high temperature zone of the plasma can also be adjusted to provide control over the properties of the resulting material. That is, the length of time the particles are exposed to the plasma determines the degree of melting of the feedstock particles (i.e., the molten particle surface compared to the innermost portion or core of the particle). By adjusting such operational variables as particle injection rate and flow rate (and conditions such as laminar or turbulent flow) within the high temperature zone, residence time can be adjusted. Equipment modifications can also be utilized to adjust residence time. For example, residence time can be adjusted by changing the cross-sectional area of ​​the plasma, e.g., by extending the plasma. In some embodiments, extending the plasma can include incorporating an extension tube into the microwave plasma device.

[0052] In some embodiments, the extension tube may include one or more cylindrical volumes extending downward into the reaction chamber, the extension tube including a stepped shape such that each successive cylindrical volume includes a larger diameter than each previous cylindrical volume as the tube extends downward into the reaction chamber. In some embodiments, the extension tube may have a conical shape that tapers radially outward as it extends downward into the reaction chamber. In some embodiments, the extension tube may include a single cylindrical volume 4. In some embodiments, a feedstock may be inserted into the extension tube at a feedstock inlet.

[0053] In some embodiments, the extension tube may include a length of about 1 foot. In some embodiments, the extension tube may be about 1 inch (2.5 cm), about 2 inches (5.1 cm), about 3 inches (7.6 cm), about 4 inches (10.2 cm), about 5 inches (12.7 cm), about 6 inches (15.2 cm), about 7 inches (17.8 cm), about 8 inches (20.3 cm), about 9 inches (22.9 cm), about 10 inches (25.4 cm), about 11 inches (27.9 cm), about 1 foot (30.5 cm), about 2 feet (61.0 cm), about 3 feet (91.4 cm), about 4 feet (121.9 cm), about 5 feet (152.4 cm), about 6 feet (182.9 cm), about 7 feet (213.4 cm), about 8 feet (243.8 cm), about 27 4.3cm (approximately 9 feet), approximately 305cm (approximately 10 feet), approximately 335.3cm (approximately 11 feet), approximately 365.8cm (approximately 12 feet), approximately 396.2cm (approximately 13 feet), approximately 426.7cm (approximately 14 feet), approximately 457.2cm (approximately 15 feet), approximately 487.7cm (approximately 16 feet), approximately 518.2cm (approximately 17 feet), approximately 54 8.6 cm (approximately 18 feet), approximately 579.1 cm (approximately 19 feet), approximately 609.6 cm (approximately 20 feet), approximately 640.1 cm (approximately 21 feet), approximately 670.6 cm (approximately 22 feet), approximately 701.0 cm (approximately 23 feet), approximately 731.5 cm (approximately 24 feet), approximately 762.0 cm (approximately 25 feet), approximately 792.5 cm (approximately 26 feet), approximately The length may include about 27 feet, about 28 feet, about 29 feet, or about 30 feet, or any value between the aforementioned values.

[0054] In some embodiments, the feedstock particles are exposed to a temperature profile within the microwave plasma between about 3727°C (4,000K) and about 7727°C (8,000K). In some embodiments, the particles are exposed to a temperature profile within the microwave plasma between about 2727°C (3,000K) and about 7727°C (8,000K). In some embodiments, one or more temperature sensors may be positioned within the microwave plasma to determine the temperature profile of the plasma.

[0055] In some embodiments, the feedstock particles need to be well dispersed in the process gas to avoid agglomeration or coalescence when the feedstock particles are melted in the reactor. In some embodiments, dispersion of the feedstock particles may be achieved by utilizing a small diameter carrier tube, which can maximize turbulence in the process gas while minimizing the carrier gas volume so as not to quench the plasma plume. In some embodiments, the feedstock particles are dispersed by feeding them with a carrier gas through a small diameter carrier tube before contacting the plasma, so that the desired particle size distribution can be achieved in the resulting powder.

[0056] In some embodiments, a carrier gas flow rate of about 60 standard liters per minute (slpm) may be used to transport the feedstock particles into the plasma through a small-diameter carrier tube. In some embodiments, a carrier gas flow rate of about 5 slpm to about 100 slpm may be used. In some embodiments, a carrier gas flow rate of about 5 slpm, about 10 slpm, about 15 slpm, about 20 slpm, about 25 slpm, about 30 slpm, about 35 slpm, about 40 slpm, about 45 slpm, about 50 slpm, about 55 slpm, about 60 slpm, about 65 slpm, about 70 slpm, about 75 slpm, about 80 slpm, about 85 slpm, about 90 slpm, about 95 slpm, about 100 slpm, or any value between the aforementioned values ​​may be used.

[0057] In some embodiments, the carrier gas and / or feedstock particles may flow through a carrier tube having an inner diameter of about 0.305 inches. In some embodiments, the carrier gas and / or feedstock particles may flow through a carrier tube having an inner diameter of about 0.050 inches to about 0.500 inches. In some embodiments, the carrier gas and / or feedstock particles may flow through a carrier tube having an inner diameter of about 0.050 inches, about 0.055 inches, about 0.060 inches, about 0.065 inches, about 0.070 inches, about 0.075 inches, about 0.080 inches, about 0.22 inches. (approximately 0.085 inches), approximately 0.23 cm (approximately 0.090 inches), approximately 0.24 cm (approximately 0.095 inches), approximately 0.25 cm (approximately 0.100 inches), approximately 0.27 cm (approximately 0.105 inches), approximately 0.28 cm (approximately 0.110 inches), approximately 0.29 cm (approximately 0.115 inches), approximately 0.30 cm (approximately 0.120 inches), approximately 0.32 cm (approximately 0.125 inches), approximately 0.33 cm (approximately 0.130 inches), approximately 0.34 cm (approximately 0.135 inches), approximately 0.36 cm (approximately 0.140 inches), approximately 0.37 cm (approximately 0.145 inches), approximately 0.38 cm (approximately 0.150 inches), approximately 0.39 cm (approximately 0.155 inches), approximately 0.41 cm (approximately 0.160 inches), approximately 0.42 cm (approximately 0.165 inches), approximately 0.43 cm (approximately 0.170 inches), approximately 0.44 cm m (approx. 0.175 inches), approx. 0.46 cm (approx. 0.180 inches), approx. 0.47 cm (approx. 0.185 inches), approx. 0.19 cm (approx. 0.190 inches), approx. 0.50 cm (approx. 0.195 inches), approx. 0.51 cm (approx. 0.200 inches), approx. 0.52 cm (approx. 0.205 inches), approx. 0.53 cm (approx. 0.210 inches), approx. 0.55 cm (approx. 0.215 inches), approx. 0.56 cm m (approx. 0.220 inches), approx. 0.57 cm (approx. 0.225 inches), approx. 0.58 cm (approx. 0.230 inches), approx. 0.60 cm (approx. 0.235 inches), approx. 0.61 cm (approx. 0.240 inches), approx. 0.62 cm (approx. 0.245 inches), approx. 0.64 cm (approx. 0.250 inches), approx. 0.65 cm (approx. 0.255 inches), approx. 0.66 cm (approx. 0.260 inches), approx. 0.67 cm (approx. 0.265 inches), approx. 0.69 cm (approx. 0.270 inches), approx. 0.70 cm (approx. 0.275 inches), approx. 0.71 cm (approx. 0.280 inches), approx. 0.72 cm (approx. 0.285 inches), approx. 0.74 cm (approx. 0.290 inches), approx. 0.75 cm (approx. 0.295 inches), approx. 0.76 cm (approx. 0.300 inches), approx. 0.77 cm (approx. 0.305 inches), approx. 0.79 cm (approx. 0.310 inches), approx. 0.80 cm (approx. 0.315 inches), approx. 0.81 cm (approx. 0.320 inches), approx. 0.83 cm (approx. 0.325 inches), approx. 0.84 cm (approx. 0.330 inches), approx. 0.85 cm (approx. 0.335 inches), approx. 0.86 cm (approx. 0.340 inches), approx. 0.88 cm (approx. 0.345 inches), approx. 0.89 cm ( Approximately 0.350 inches, approximately 0.90 cm (approximately 0.355 inches), approximately 0.91 cm (approximately 0.360 inches), approximately 0.93 cm (approximately 0.365 inches), approximately 0.94 cm (approximately 0.370 inches), approximately 0.95 cm (approximately 0.375 inches), approximately 0.97 cm (approximately 0.380 inches), approximately 0.98 cm (approximately 0.385 inches), approximately 0.99 cm (approximately 0.390 inches), approximately 1.00 cm (approximately 0.395 inches), approximately 1.02 cm (approximately 0.400 inches), approximately 1.03 cm (approximately 0.405 inches), approximately 1.04 cm (approximately 0.410 inches), approximately 1.05 cm (approximately 0.415 inches), approximately 1.07 cm (approximately 0.420 inches), approximately 1.08 cm (approximately 0.425 inches), approximately 1.09 cm (approximately 0.430 inches), approximately 1.10 cm (approximately 0.435 inches), approximately 1.12 cm (approximately 0.440 inches), approximately 1.13 cm (approximately 0.445 inches), approximately 1.14 cm (approximately 0.450 inches), approximately 1.16 cm (approximately 0.455 inches), approximately 1.17 cm (approximately 0.460 inches), approximately 1.18 cm (approximately 0.465 inches), approximately 1.19 cm (approximately 0.470 inches), approximately 1.20 cm (approximately 0.475 inches), approximately 1.22 cm (approximately 0.The fluid may flow through a carrier tube having an inner diameter of about 480 inches, about 0.485 inches, about 0.490 inches, about 0.495 inches, about 0.500 inches, or any value between the aforementioned values.

[0058] In some embodiments, particles directed toward the hottest portion of the plasma plume may generate a high percentage of nanoparticles in the collection chamber. In some embodiments, without being limited by theory, it is believed that the particles may heat up too quickly, and the carbon dioxide generated from pyrolysis may not escape quickly enough, resulting in particle explosion. In some embodiments, heating the particles more gently and evenly may prevent particle explosion. In some embodiments, slower and more even heating of the particles may be achieved by moving the delivery nozzle vertically and / or horizontally away from the hottest portion of the plasma.

[0059] In some embodiments, all of the lithium carbonate is converted to lithium oxide. However, carbon dioxide may be inadequately reabsorbed on the surface of the particles, forming a surface lithium carbonate layer up to about 1 micron deep. TGA analysis has shown that CO reuptake is rapid at temperatures between about 400°C and about 800°C (the decomposition temperature range). Therefore, in some embodiments, the process is optimized to avoid that temperature range using a quench. In some embodiments, the quench moves the particles very rapidly through the decomposition temperature range to avoid CO reuptake. Figure 4 shows the mass uptake of particles after exposure to CO after conversion of the particles to LiO according to some embodiments herein.

[0060] Spheroidization In some embodiments, the final particles achieved by plasma processing may be spherical or Although the term may be used interchangeably, the terms may be used interchangeably. Advantageously, by utilizing the significant and specific disclosures pertaining to each of the different raw materials disclosed, all of the raw materials can be converted into spherical powders. In some embodiments, sphericity may be measured by taking SEM images of the generated particles and measuring 100 adjacent particles. The sphericity of the powder may be interpreted as the average sphericity of 100 particles.

[0061] Embodiments of the present disclosure are directed to producing particles that are substantially spherical or spheroidal, or that have undergone significant spheroidization. In some embodiments, spherical, spheroidal, or spheroidized particles refer to particles that have a sphericity greater than a certain threshold. The sphericity of a particle can be determined by the following equation:

number

number

[0062] In some embodiments, the particles can have a sphericity (also referred to herein as sphericity factor) of greater than 0.5, 0.6, 0.7, 0.75, 0.8, 0.9, 0.91, 0.95, or 0.99 (or greater than about 0.5, about 0.6, about 0.7, about 0.75, about 0.8, about 0.8, about 0.91, about 0.95, or about 0.99). In some embodiments, the particles can have a sphericity of 0.75 or greater, or 0.91 or greater (or about 0.75 or greater, or about 0.91 or greater). In some embodiments, particles can have a sphericity of less than 0.5, 0.6, 0.7, 0.75, 0.8, 0.9, 0.91, 0.95, or 0.99 (or less than about 0.5, about 0.6, about 0.7, about 0.75, about 0.8, about 0.8, about 0.91, about 0.95, or about 0.99). In some embodiments, particles are considered to be spherical, spheroidal, or spheroidized if they have a sphericity equal to or greater than any of the foregoing sphericity values; in some preferred embodiments, particles are considered to be spherical if their sphericity is about 0.75, or about 0.75 or greater, or about 0.91, or about 0.91 or greater.

[0063] In some embodiments, the median sphericity of all particles in a given powder may be greater than 0.5, 0.6, 0.7, 0.75, 0.8, 0.9, 0.91, 0.95, or 0.99 (or greater than about 0.5, about 0.6, about 0.7, about 0.75, about 0.8, about 0.8, about 0.91, about 0.95, or about 0.99). In some embodiments, the median sphericity of all particles in a given powder may be less than 0.5, 0.6, 0.7, 0.75, 0.8, 0.9, 0.91, 0.95, or 0.99 (or less than about 0.5, about 0.6, about 0.7, about 0.75, about 0.8, about 0.8, about 0.91, about 0.95, or about 0.99). In some embodiments, a powder is considered to be spheroidized if all or a threshold percentage of the particles measured for a given powder (as described by any of the percentages below) have a median sphericity greater than or equal to any of the aforementioned sphericity values, and in some preferred embodiments, a powder is considered to be spheroidized if all or a threshold percentage of the particles have a median sphericity of about 0.75, or about 0.75 or greater, or about 0.91, or about 0.91 or greater.

[0064] In some embodiments, the percentage of particles in a powder that may exceed a given sphericity threshold as described above may be greater than 50%, 60%, 70%, 80%, 90%, 95%, or 99% (or greater than about 50%, about 60%, about 70%, about 80%, about 90%, about 95%, or about 99%). In some embodiments, the percentage of particles in a powder that may exceed a given sphericity threshold as described above may be less than 50%, 60%, 70%, 80%, 90%, 95%, or 99% (or less than about 50%, about 60%, about 70%, about 80%, about 90%, about 95%, or about 99%).

[0065] Particle size distribution and sphericity may be determined by any suitable known technique, such as SEM, optical microscopy, dynamic light scattering, laser diffraction, manual sizing using image analysis software, e.g., about 15-30 scales per image on at least three images of the same material section or sample, and any other technique.

[0066] Particle size distributions referred to herein may be referred to in terms of D50 or in terms of average particle size. The average particle size may be calculated as the mean of the distribution of particles. D50 is also referred to as the median particle diameter or median particle size. For example, a powder sample with D50 = 5 μm means that 50% of the particles are greater than 5 μm and 50% of the particles are less than 5 μm. In some embodiments, the D50 of the particles may be less than 500 μm. In some embodiments, the D50 (mean or median) of the particles is about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 25 μm, about 30 μm, about 35 μm, about 40 μm, about 45 μm, about 50 μm, about 55 μm, about 60 μm, about 65 μm, about 70 μm, about 75 μm, about 80 μm, about 85 μm, about 90 μm, about 95 μm, about 100 μm, about 105 μm, about 110 μm, about 115 μm, about 120 μm, about 125 μm, or about 130 μm. μm, approximately 130 μm, approximately 135 μm, approximately 140 μm, approximately 145 μm, approximately 150 μm, approximately 155 μm, approximately 160 μm, approximately 165 μm, approximately 170 μm, approximately 175 μm, approximately 180 μm, approximately 185 μm, approximately 190 μm, approximately 195 μm, approximately 200 μm, approximately 205 μm, approximately 210 μm, approximately 215 μm, approximately 220 μm, approximately 225 μm, approximately 230 μm, approximately 235 μm, approximately 240 μm, approximately 245 μm, approximately 250 μm, approximately 255 μm, approximately 260 μm, approximately 265 μm, approximately 270 μm, approximately 275 μm, approximately 280 μm, approximately 285 μm, approximately 290 μm, approximately 295 μm, approximately 300 μm, approximately 305 μm, approximately 310 μm, approximately 315 μm, approximately 320 μm, approximately 325 μm, approximately 330 μm, approximately 335 μm, approximately 340 μm, approximately 345 μm, approximately 350 μm, approximately 355 μm, approximately 360 μm, approximately 365 μm, approximately 370 μm, approximately 375 μm, approximately 380 μm, approximately 385 μm, about 390 μm, about 395 μm, about 400 μm, about 405 μm, about 410 μm, about 415 μm, about 420 μm, about 425 μm, about 430 μm, about 435 μm, about 440 μm, about 445 μm, about 450 μm, about 455 μm, about 460 μm, about 465 μm, about 470 μm, about 475 μm, about 480 μm, about 485 μm, about 490 μm, about 495 μm, about 500 μm, or any value between the aforementioned values.

[0067] porosity According to various embodiments herein, the lithium oxide particles have low porosity. For example, in various embodiments, the lithium oxide particles are substantially non-porous. Porosity may be measured in terms of BET (Bernauer-Emmett-Teller) surface area or apparent bulk density. When porosity is measured in terms of apparent density, it is expressed in g / cm. 3 , g / cc , or kg / m 3 Apparent bulk density may be measured as the total mass of a particle divided by the particle's external or apparent volume. In the powder art, apparent density is sometimes referred to as volume density or particle density. The apparent densities described herein may be measured at atmospheric pressure via tap or bulk density measurements.

[0068] BET surface area can be measured as the physical adsorption of a gas (typically a noble gas) onto the surface of a particle at cryogenic temperatures. BET surface analysis is reported in units of area per mass of sample (m 2 / g). However, the specific surface area is measured in units of area per volume of sample (m 2 / cm 3 ) can also be expressed as

[0069] In some embodiments, lithium oxide is present at 0.5 g / cm 3 Exceeds 0.8g / cm 3 Exceeds 1.0g / cm 3 Exceeds 1.5g / cm 3 or more than 2.0 g / cm 3In some embodiments, lithium oxide is provided having an apparent density of about 2 g / cc to about 5 g / cc and a porosity of less than 10%, or about 0.1% to about 10%, as measured by a compaction process. In some embodiments, the porosity of the lithium oxide is about 0.1%, about 0.35%, about 0.6%, about 0.85%, about 1.1%, about 1.35%, about 1.6%, about 1.85%, about 2.1%, about 2.35%, about 2.6%, about 2.85%, about 3.1%, about 3.35%, about 3.6%, about 3.85%, about 4.1%, about 4.35%, about 4.6%, or about 4.85%. , about 5.1%, about 5.35%, about 5.6%, about 5.85%, about 6.1%, about 6.35%, about 6.6%, about 6.85%, about 7.1%, about 7.35%, about 7.6%, about 7.85%, about 8.1%, about 8.35%, about 8.6%, about 8.85%, about 9.1%, about 9.35%, about 9.6%, about 9.85%, about 10%, or any value between the aforementioned values.

[0070] Additional Embodiments In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be apparent that various modifications and changes can be made thereto without departing from the broader spirit and scope of the invention. The specification and drawings are, therefore, to be regarded in an illustrative rather than a restrictive sense.

[0071] Moreover, while the present invention has been disclosed in connection with specific embodiments and examples, those skilled in the art will recognize that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments and / or uses of the invention, as well as obvious modifications and equivalents thereof. Additionally, while several modifications of embodiments of the invention have been shown and described in detail, other modifications within the scope of the invention will be readily apparent to those skilled in the art based on this disclosure. It is also contemplated that various combinations or subcombinations of specific features and aspects of the embodiments may be made and still fall within the scope of the invention. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another to form varying modes of embodiments of the disclosed invention. Any methods disclosed herein need not be performed in the order listed. Therefore, the scope of the invention disclosed herein should not be limited by the specific embodiments described above.

[0072] It will be recognized that the systems and methods of the present disclosure each have multiple innovative aspects, no single one of which is solely responsible for or required for the desired attributes disclosed herein. The various features and steps described above may be used independently of one another or may be combined in multiple ways. All possible combinations and subcombinations are intended to be within the scope of the present disclosure.

[0073] Certain features that are described in this specification in the context of separate embodiments may also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment may also be implemented in combination in a single embodiment. may also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, while features may be described above as working in a particular combination and may even be initially claimed as such, one or more features from the claimed combination may in some instances be deleted from the combination, and the claimed combination may be directed to a subcombination or a variation of a subcombination. No feature or group of features is necessary or essential to every embodiment.

[0074] Unless specifically stated otherwise within the context in which it is used or understood otherwise, it will be recognized that conditional language used herein, such as "can," "could," "could," "could," "for example," and the like, is generally intended to convey that certain embodiments include certain features, elements, and / or steps and that other embodiments do not. Thus, such conditional language does not generally imply that those features, elements, and / or steps are required for one or more embodiments, regardless of whether those features, elements, and / or steps are included in or should be performed in any particular embodiment, or that one or more embodiments necessarily include logic for determining, with or without author provision or facilitation. The terms "including," "including," "having," and the like, are synonymous and used inclusively in an open-ended manner and do not exclude additional elements, features, acts, operations, and the like. Additionally, the term "or" is used in an inclusive sense (and not an exclusive sense), so that, for example, when used to connect a list of elements, the term "or" means one, some, or all of the elements in that list. Additionally, the articles "a," "an," and "the" used in this application and the appended claims should be interpreted to mean "one or more" or "at least one" unless expressly stated otherwise. Similarly, while operations may be depicted in the figures in a particular order, it should be recognized that such operations need not be performed in the particular order or sequential order depicted, or that all depicted operations need not be performed to achieve desirable results. Furthermore, the figures may schematically depict one or more exemplary steps in flow diagram form. However, other operations not depicted may be incorporated into the schematically depicted exemplary methods and steps. For example, one or more additional operations may be performed before, after, concurrently with, or during any of the illustrated operations. Additionally, operations may be rearranged or reordered in other embodiments. In certain situations, multitasking and parallel processing may be advantageous.Moreover, the separation of various system components in the above-described embodiments should not be understood to require such separation in all embodiments, and it should be understood that the described program components and systems generally may be integrated together in one software product or packaged in multiple software products. Additionally, other embodiments are within the scope of the following claims. In some instances, the actions recited in the claims may be performed in a different order and still achieve desirable results.

[0075] Furthermore, while the methods and devices described herein are susceptible to various modifications and alternative forms, specific examples thereof have been shown in the drawings and are described in detail herein. However, it should be understood that the invention is not limited to the particular forms or methods disclosed, but rather the invention is intended to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the various implementations described and the appended claims. Furthermore, the disclosure herein of any particular feature, aspect, method, property, characteristic, property, attribute, element, or the like associated with an implementation or embodiment can be used in all other implementations or embodiments described herein. Any method disclosed herein need not be performed in the order listed. While a method disclosed herein may include specific acts performed by a practitioner, the method may also include, explicitly or by implication, third-party instruction in any of those acts. The scope disclosed herein also encompasses any overlaps, sub-sets, or sub-sets thereof. "includes partial ranges, and combinations. Language such as "up to," "at least," "greater than," "less than," "between," and the like, is inclusive of the recited number. Numbers preceded by terms such as "about" or "approximately" are inclusive of the recited number and should be interpreted in the context (e.g., as precisely as reasonably possible under the circumstances, e.g., ±5%, ±10%, ±15%, etc.). For example, "about 3.5 mm" includes "3.5 mm." Phrases preceded by terms such as "substantially" are inclusive of the recited number and should be interpreted in the context (e.g., as much as reasonably possible under the circumstances). For example, "substantially constant" includes "constant." Unless otherwise stated, all measurements are conducted at standard conditions, including temperature and pressure.

[0076] As used herein, phrases referring to "at least one" of a list of items refer to any combination of those items containing one member. By way of example, "at least one of A, B, or C" is intended to cover A, B, C, A and B, A and C, B and C, and A, B, and C. In other instances, it is understood that conjunctive language such as "at least one of X, Y, and Z" is generally used to convey that, in that context, an item, term, etc., can be at least one of X, Y, and Z, unless specifically stated otherwise. Thus, such conjunctive language does not generally suggest that a particular embodiment requires at least one of X, at least one of Y, and at least one of Z, respectively, to be present. Headings provided herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the devices and methods disclosed herein.

[0077] Therefore, the scope of the claims should not be limited to the embodiments shown herein, but should be accorded the broadest scope consistent with this disclosure, the principles and novel features disclosed herein.

Claims

1. One or more lithium oxides (Li ２ O) a lithium oxide powder comprising particles, at least 50% of the lithium oxide particles have a sphericity greater than 0.75; the lithium oxide particles have an average particle size of less than about 500 μm; Lithium oxide powder.

2. 10. The composition of claim 1, wherein the lithium oxide particles have an average particle size of less than about 250 μm.

3. 10. The composition of claim 1, wherein the lithium oxide particles have an average particle size of less than about 100 μm.

4. 10. The composition of claim 1, wherein at least 50%, at least 75%, or at least 90% of the lithium oxide particles have a sphericity greater than 0.

9.

5. 10. The composition of claim 1, wherein at least 50%, at least 75%, or at least 90% of the lithium oxide particles have a sphericity greater than 0.

95.

6. 10. The composition of claim 1, wherein the one or more lithium oxide particles have a bulk average purity of at least about 20%, at least about 25%, at least about 40%, at least about 60%, at least about 80%, or at least about 95%.

7. 10. The composition of claim 1, wherein the one or more lithium oxide particles have a D50 particle size of about 5 to 15 μm.

8. 10. The composition of claim 1, wherein at least 90% to about 99.9% of the lithium oxide particles comprise standalone particles.

9. 1. A process for producing lithium oxide particles, said process comprising: introducing one or more lithium-containing precursor powder materials into a microwave-generated plasma; contacting the one or more lithium precursor powder materials with the microwave-generated plasma; cooling and solidifying the lithium precursor to form one or more spherical lithium oxide particles; and recovering the one or more spherical lithium oxide particles, wherein the one or more spherical lithium oxide particles have an average particle size of less than about 500 μm.

10. 10. The process of claim 9, wherein the one or more spherical lithium oxide particles have an average particle size between about 5 and 500 μm.

11. 10. The process of claim 9, wherein the one or more spherical lithium oxide particles have a D50 particle size of between about 5 and 50 μm.

12. 10. The process of claim 9, wherein the one or more spherical lithium oxide particles have a D50 particle size of about 5 to 15 μm.

13. 10. The one or more spherical lithium oxide particles have a median sphericity greater than 0.

5.

9. The process described in

14. 10. The process of claim 9, wherein the one or more spherical lithium oxide particles have a median sphericity greater than 0.

8.

15. 10. The process of claim 9, wherein the one or more spherical lithium oxide particles have a median sphericity greater than 0.

95.

16. 10. The process of claim 9, wherein the bulk average purity of the one or more spherical lithium oxide particles is at least about 20%, at least about 25%, at least about 40%, at least about 60%, at least about 80%, or at least about 95%.

17. 10. The process of claim 9, wherein the one or more spherical lithium oxide particles have a bulk average purity of at least 99%.

18. 10. The process of claim 9, wherein the one or more spherical lithium oxide particles have an average particle size of less than about 250 μm.

19. 10. The process of claim 9, wherein the one or more spherical lithium oxide particles have an average particle size of less than about 100 μm.

20. 10. The process of claim 9, further comprising forming the one or more lithium oxide particles into a lithium ion battery active material.

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