Aluminum activation devices, systems, and methods of use thereof

Abstract

Described herein are devices, systems, and methods for producing water-reactive aluminum compositions. In some embodiments, a system for activating a plurality of fuel particles with an activating metal alloy is described. In some embodiments, the system includes a heating chamber, a piston configured to rotate about a longitudinal axis of the piston, a second chamber disposed within the heating chamber and coupled to the piston to rotate therewith, and a ramp extending at least partially along the interior surface. In some embodiments, the ramp has a tapered surface forming an angle greater than zero degrees relative to the longitudinal axis of the piston. In some embodiments, the system includes a mixing chamber disposed within the second chamber and coupled to the ramp. In some embodiments, the mixing chamber has a sealable port configured to receive the plurality of fuel particles and the activating metal alloy.

Description

ALUMINUM ACTIVATION DEVICES, SYSTEMS, AND METHODS OF USETHEREOFCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 672,931, filed on July 18, 2024, the disclosure of which is hereby incorporated by reference in its entirety for all purposes.BACKGROUND

[0002] Aluminum is a promising candidate for energy storage due to its high energy density, abundance, low cost, non-toxicity, non-volatility, and non-reactivity in storage. One method of extracting the energy from aluminum is to react the aluminum with water to form hydrogen and heat as described in Reaction 1 or Reaction 2.• Al + 2 H2O — > 1.5(Reaction 1)• Al + 3 H2O — > 1.5(Reaction 2)

[0003] Untreated aluminum will typically not react with water due to the highly passivating oxide layer that forms on its surface. However, the oxide layer may be disrupted by an appropriate catalyst, thereby activating the aluminum to make it water-reactive.

[0004] There exists a need to automate activation of aluminum, as well as to optimize activation parameters for process efficiency and performance of the resulting activating aluminum, and to provide flexibility in the catalysts that may be used to produce the activated aluminum.BRIEF SUMMARY

[0005] Systems, methods, and devices described herein describe activation of a plurality of fuel particles with an activating metal alloy. In one aspect, a system for activation of a plurality of fuel particles with an activating metal alloy is described. In some embodiments, the system includes a heating chamber having a first interior cavity, a piston configured to rotate about a longitudinal axis of the piston, a second chamber having a second interior cavity defined by the interior surface of the second chamber, wherein the second chamber is disposed within the first cavity and coupled to the piston to rotate therewith, a ramp extending at least partially along the interior surface, the ramp having a tapered surface forming an angle greater than zero degrees relative to the longitudinal axis of the piston, and a mixing chamber having a third interior cavity, the mixing chamber disposed within the second interior cavity and coupled to the ramp, wherein the mixing chamber comprises asealable port configured to receive the plurality of fuel particles and the activating metal alloy. In some embodiments, the system includes a heating chamber having a first interior cavity, a piston configured to rotate about a longitudinal axis of the piston, a mixing chamber having a third interior cavity defined by the interior surface of the mixing chamber, wherein the mixing chamber is disposed within the first cavity and coupled to the piston to rotate therewith, wherein the mixing chamber is disposed at an angle greater than zero relative to the longitudinal axis of the piston, wherein the mixing chamber comprises a sealable port configured to receive the plurality of fuel particles and the activating metal alloy. In some embodiments, the system further includes a second chamber disposed within the heating chamber having a second interior cavity configured to receive the mixing chamber. In some embodiments, the first interior cavity is configured to be heated to and / or maintained at a desired temperature. In some embodiments, the desired temperature is between 20 °C and 200 °C, 25 °C to 200 °C, or 50 °C to 200 °C. In some embodiments, the third interior cavity includes one or more baffles extending along the longitudinal axis of the mixing chamber and extending outward from third interior cavity surface towards the interior cavity. In some embodiments, the mixing chamber is configured to be sealably filled with an inert gas. In some embodiments, the inert gas is argon. In some embodiments, the inert gas is selected from a group consisting of argon, helium, and nitrogen, or a combination of any two or more thereof. In some embodiments, the plurality of fuel particles includes aluminum. In some embodiments, the activating metal alloy comprises gallium, indium, bismuth, and / or tin. In some embodiments, the piston is coupled to an actuator configured to rotate at least one of the heating chamber, the second chamber, the mixing chamber, or any combination thereof between 2-30 rotations per minute. In some embodiments, the second chamber comprises a mesh material. In some embodiments, an inner surface of the third interior cavity comprises an abrasive coating configured to induce surface abrasion of the plurality of fuel particles. In another aspect, a method for activation of the plurality of fuel particles is described herein. In some embodiments, the method includes receiving the fuel activation system described above. In some embodiments, the method includes introducing the plurality of fuel particles through the sealable port of the mixing chamber and into the third interior cavity, introducing the activating metal alloy through the sealable port of the mixing chamber and into the third interior cavity, sealing the sealable port, and rotating the piston about the longitudinal axis of the piston, thereby rotating the mixing chamber at the angle relative to the longitudinal axis of the piston and mixing the plurality of fuel particles with the activating metal alloy.

[0006] In another aspect, a system for activating a plurality of fuel particles is described herein. In some embodiments, the system comprises a heating chamber having a first interior cavity configured to be heated to a desired temperature, a mixing chamber having a second interior cavity, the mixing chamber disposed within the first interior cavity and configured to receive the plurality of fuel particles and an activating metal alloy, a piston coupled to the heating chamber, the mixing chamber, or both the heating chamber and the second chamber, and an actuator coupled to the piston, wherein the actuator is configured to rotate the piston about a longitudinal axis of the piston thereby mixing the plurality of fuel particles and activating metal alloy. In some embodiments, the system includes a first wheel, belt, or track coupled with the piston, such that the first wheel, belt, or track rotates about the longitudinal axis of the piston as the piston rotates, wherein the first wheel, belt, or track is configured to contact the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber and to rotate the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber. In some embodiments, the system includes a second wheel, belt, or track spaced apart from the first wheel, belt, or track and coupled with the piston such that the second wheel, belt, or track rotates about the longitudinal axis of the piston as the piston rotates, wherein the second wheel, belt, or track is configured to contact the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber and to rotate the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber. In some embodiments, the system includes a third wheel, belt, or track spaced apart from the first wheel, belt, or track and the second wheel, belt, or track, wherein the third wheel, belt, or track is configured to support, rotate with, and contact the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber. In some embodiments, the system includes a fourth wheel, belt, or track spaced apart from the first wheel, belt, or track, the second wheel, belt, or track, and third wheel, belt, or track, wherein the fourth wheel, belt, or track is configured to support, rotate with, and contact the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber. In some embodiments, at least one of the first wheel, belt, or track, the second wheel, belt, or track, the third wheel, belt, or track, and the fourth wheel, belt, or track comprises a wheel. In some embodiments, at least one of the first wheel, belt, or track, the second wheel, belt, or track, the third wheel, belt, or track, and the fourth wheel, belt, or track is fixedly attached to a frame mounted to an interior surface of the first interior cavity. In some embodiments, a coupling is configured to couple the actuator with the piston, thereby providing rotation to the piston when the actuator is engaged with the coupling. In some embodiments, the coupling comprises a spider gear. Insome embodiments, the first interior cavity is configured to be heated to and / or maintained at a desired temperature. In some embodiments, the desired temperature is between 20 °C to 200 °C, 25 °C to 200 °C, or 50 °C to 200 °C. In some embodiments, the plurality of fuel particles comprise aluminum. In some embodiments, the activating metal alloy comprises gallium, indium, bismuth and / or tin. In some embodiments, the piston is configured to rotate at least one of the first wheel, belt, or track, the second wheel, belt, or track, or both thereby rotating the heating chamber, the mixing chamber, or both between 2-30 rotations per minute. In some embodiments, the mixing chamber comprises a mesh material. In some embodiments, the second interior cavity comprises one or more baffles extending along the longitudinal axis of the second chamber and extending outward from the second interior cavity surface towards the interior cavity. In some embodiments, the mixing chamber is configured to be sealably filled with an inert gas. In some embodiments, the inert gas is argon. In some embodiments, the inert gas is selected from a group consisting of argon, helium, and nitrogen, or a combination of any two or more thereof. In some embodiments, an inner surface of the second interior cavity comprises an abrasive coating configured to induce surface abrasion of the plurality of fuel particles. In some embodiments, a method for activation of the plurality of fuel particles is described herein. In some embodiments, the method includes setting up the fuel activation system described above. In some embodiments, the method includes introducing the plurality of fuel particles and the activating metal alloy into the second interior cavity, rotating the piston with the actuator to cause the piston to rotate about the longitudinal axis of the piston, thereby rotating at least one of the heating chamber and the mixing chamber.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0007] FIG. 1 illustrates a first example of an angled fuel activation system, according to embodiments described herein.

[0008] FIG. 2A illustrates a second example of a fuel activation system, according to embodiments described herein.

[0009] FIG. 2B illustrates an example of the rotation system of FIG. 2A, according to embodiments described herein.

[0010] FIG. 2C illustrates an example of the actuation system of FIG. 2A, according to embodiments described herein.DETAILED DESCRIPTION

[0011] Many existing processes for activating aluminum are performed manually. As such, they are labor intensive, result in nonuniformity and inconsistency, and / or are difficult to scale up in size.

[0012] To avoid these shortcomings, it is desirable to develop devices, systems, and methods of activating aluminum that are automated, scalable, rapid, and robust.

[0013] The present disclosure provides devices, systems, and processes for activating aluminum with the use of an activating metal alloy (catalyst). The contemplated processes may make aluminum reactive with water or steam as described in Reaction 1 or Reaction 2.

[0014] Applications of the contemplated devices, systems, and processes may be used for primary aluminum, secondary aluminum, or any feedstock containing metallic aluminum. Some examples of various applicable feedstock include but are not limited to: pure aluminum, aluminum alloys, dross from aluminum smelting processes, dross from aluminum recycling processes, aluminum components that don’t meet product specifications or pass quality control, aluminum foils, and household waste food containers. Exact process conditions may be tuned depending on the chemistry, microstructure and physical morphology of the feedstock.

[0015] The terms “catalyst” and “activating metal alloy”, are used interchangeably herein and refer to a metallic alloy capable of diffusing in metallic aluminum and disrupting the superficial and interstitial aluminum oxide of metallic aluminum.

[0016] As used herein, a catalyst or activating metal alloy that consists “essentially of’ one or more components is to be understood as consisting of said components and no more than trace amounts of any additional components (e.g., less than 0.5% by mass of each additional component).

[0017] The term “feedstock”, as used herein, refers to any starting material which contains metallic aluminum including but not limited to pure aluminum, aluminum alloys, primary or secondary aluminum, and waste product which contains a significant amount (e.g., at least 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, or 80% by weight) of metallic aluminum. Feedstock may contain additional components including but not limited to plastic, other metals, ceramics, and organic compounds.

[0018] The term “fuel particle” or “fuel particles” as used herein, refers to any starting material which contains metallic aluminum including but not limited to pure aluminum, aluminum alloys, primary or secondary aluminum, and waste product which contains a significant amount (e.g., at least 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, or 80% by weight) of metallic aluminum. Feedstock may contain additional components including butnot limited to plastic, other metals, ceramics, and organic compounds. In a non-limiting example, fuel particles are materials containing metallic aluminum which have been compressed and / or shaped into a desired shape having a desired average diameter and particle size distribution. In another non-limiting example, fuel particles are materials that consist of or comprise feedstock.

[0019] The term “activated fuel”, as used herein, refers to an activated aluminum composition formed by treating aluminum or an alloy thereof with an activating metal alloy. When water is introduced to the activated fuel, the aluminum disintegrates to expose the interior volume to the water, and a rapid hydrolysis reaction occurs.

[0020] The term “room temperature” as used herein refers to 20 °C.

[0021] The term “aluminum foil” as used herein refers to aluminum in the form of a sheet having a thickness of less than or equal 0.2 mm.

[0022] The term “about,” as used herein, means approximately, in the region of, roughly, or around. Unless otherwise stated for a numerical value noted, when the term “about” is used in conjunction with a numerical range, it modifies that range by extending the boundaries above and below the numerical values set forth. Unless otherwise stated for a numerical value noted, the term “about” is used herein to modify a numerical value above and below the stated value by a variance of 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 15%, 20%, 25%, or 50%. For nonlimiting example, a range of “about 2 to about 20” can mean 1.98 to 22, or 1 to 30, or other ranges therebetween. Unless otherwise stated for a percentage range noted, when the term “about” is used in conjunction with a percentage range, it modifies that range by extending the boundaries above and below the percentages set forth. Unless otherwise stated for the percentage noted, the term “about” is used herein to modify a percentage above and below the stated percentage by 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 15%, 20%, 25%, or 50% (as an absolute, which may be limited to 0% as a minimum), or by a percentage of the stated percentage i.e. 1% 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 15%, 20%, 25%, or 50% of the percentage. For nonlimiting example, a range of “about 2% to about 20%” can mean 1% to 21%, or 0% to 70%, or other ranges therebetween, or 1.98% to 22%, or 1% to 30% (as a percentage of the percentage range). For nonlimiting example, a percentage value of “about 30%” can mean 29% to 31%, or 0% to 80%, or other ranges therebetween, or 27% to 33%, or 15% to 45% (as a percentage of the percentage value), or other ranges therebetween. Unless otherwise stated for a numerical range noted, numerical ranges recited herein by endpoints include all numbers and fractions subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.90, 4, and 5). It is alsoto be understood that all numbers and fractions thereof are presumed to be modified by the term “about.”

[0023] As used herein an average particle diameter may be described in terms of the mean particle size characterized by any one of a sphere of ideal volume (dv), a sphere of identical weight (dw), a sphere of identical minimum length (dmin), a sphere passing same sieve aperture (dsieVe), a sphere of identical maximum length, a sphere of identical surface area (ds), a sphere that diffuses at the same rate as the particle in a fluid (dh), or a sphere of identical sedimentation rate (dsed). The type of characterization of particle size may be determined by a skilled person in the art depending on how the particles are formed and their size. In a non-limiting example, pellet shaped particles having a diameter of 20 mm may be characterized by a sphere passing same sieve aperture (dsieve).

[0024] As used herein an “average” size of a population of particles may be described in terms of the percentile of particles smaller than a given diameter. For example, a D10 value, or the 10th percentile, signifies the particle size below which 10% of the population's particles are found. In another example, the D50 value is the 50thpercentile, also known as the median particle size, is the size at which 50% of the population's particles consists of particles smaller than this size. In a further example, the D90 value, or the 90th percentile, indicates the particle size below which 90% of the population's particles are located. In some embodiments, one percentile is used to define the average particle size. In some embodiments, all three percentiles are used to describe the size distribution of particles within a population.

[0025] Many different techniques known to those skilled in the art may be used to characterize the average diameter of a population and the distribution of particle sizes within a population. For example, a population of particles may be passed through one or more sieves, each sieve progressively smaller mesh sizes (dsieve).Activating Metal Alloy

[0026] The devices, systems, and methods described herein are useful for activating aluminum using an activating metal alloy.

[0027] In some embodiments, the activating metal alloy comprises gallium and / or indium.

[0028] In some embodiments, the activating metal alloy is a eutectic mixture of gallium and indium (e.g., 80% gallium, 20% indium).

[0029] In some embodiments, the activating metal alloy further comprises tin and / or bismuth.

[0030] In some embodiments, the activating metal alloy is a non-eutectic alloy comprising bismuth, tin, indium, and gallium.

[0031] In some embodiments, the activating metal alloy comprises bismuth, tin, and indium and does not comprise gallium.Systems and Devices for Activating Aluminum

[0032] FIG. 1 illustrates an example of a batch fuel activation system 102 according to embodiments described herein. The process as described herein may be a batch process. The term “batch” is generally understood by persons skilled in the present field of art of the present application to refer to a process that does not have a steady state of material added to the batch fuel activation system 102 and / or exiting the batch fuel activation system 102. As used herein, a “batch process" refers to a process, or system or device configured to implement said process, where one or more process conditions are changing over time, such process conditions including any one or more of (i) addition of feedstock, fuel particles, and / or metal activating alloy (e.g., catalyst) (ii) concentrations of reagents in the batch fuel activation system 102, and (iii) temperatures, pressures, pH, and / or flow rates of inlets and / or outlets. In a non-limiting example, a batch process may include the steps of opening a mixing chamber 116, adding a plurality of fuel particles, ceasing the addition of fuel particles, and sealing the mixing chamber 116.

[0033] In some embodiments, the plurality of fuel particles comprise aluminum. In some embodiments, one or more fuel particles within the plurality of fuel particles comprises aluminum which has been compressed into a formed shape. For example, the one or more fuel particles within the plurality of fuel particles may be compressed into a formed shape using a die and / or a hydraulic press. In some embodiments, the hydraulic press is an aluminum bailer. In some embodiments, the formed shape is a cylinder. In some embodiments, the formed shape is a sphere. In some embodiments, the formed shape is a cubic square. In some embodiments, the formed shape is a cubic rectangle or brick. In some embodiments, the formed shape is a briquette having a first end, a second end, and a cylindrical surface extending therebetween. In some embodiments, the first end and the second end have circular cross-sectional areas. In some embodiments, at least one of the first end and the second end have a convex or concave curvature. In some embodiments, at least one of the first end and the second end have a convex or concave curvature. In some embodiments, at least one of the first end and the second end have a substantially flat surface. In some embodiments, the formed shape is selected from a group consisting of a sphere, a cylinder, a brick, a briquette, a cube, a cubic rectangle, a pyramid, a prism, a cone,a cuboid, a hemisphere, a hexagonal pyramid, an octahedron, and an ellipsoid. In some embodiments, the plurality of fuel particles comprises a mixture of particles having different formed shapes.

[0034] In some embodiments, one or more fuel particles within the plurality of fuel particles comprises aluminum and / or feedstock which has been shredded into a fibrous particle. As used herein a fibrous particle is a particle is a particle in which a first dimension extending along the longitudinal axis is at least twice as long a second dimension extending perpendicular to the first dimension. In some embodiments, the plurality of fuel particles comprises a mixture of particles having one or more formed shapes and fibrous particle.

[0035] In some embodiments, a method of forming a plurality of fuel particles is described herein. In some embodiments, the method comprises the step of adding aluminum and / or feedstock into a die. In some embodiments, the die compresses the aluminum and / or feedstock into a formed shape. In some embodiments, the die is opened the formed particle is released and / or removed.

[0036] In some embodiments, the plurality of fuel particles are shredded, compressed, and / or shaped into a formed shape or fiber having a desired average diameter and a desired particle size distribution. In some embodiments, the desired average diameter is greater than 1 mm. In some embodiments, the desired average diameter is greater than 5 mm. In some embodiments, the desired average diameter is less than 1 meter. In some embodiments, the desired average diameter is less than 5 meters. In some embodiments, the desired average diameter is between 1-5000 mm. In some embodiments, the desired average diameter is between 1-5, 5-50, 50-100, 100-200, 200-500, 500-1000, 1000-5000 mm. The plurality of fuel particles may comprise a distribution of particle sizes.

[0037] For example, a briquette shaped particle may have a 3.5 inch diameter and a height between 1-3 inches. In some embodiments, a pellet shaped particle may have a 20 mm diameter. In some embodiments, a disk shaped particle may have a height and a diameter each between 1-5 mm. In some embodiments, a cube shaped particle has a length, a width and a height between 0.5-2.0 meters.

[0038] The type of characterization of particle size may be determined by a skilled in the art depending on how the particles are formed, diameter, and distribution of particle sizes. In a non-limiting example, pellet shaped particles having a diameter between 1-5 mm may be characterized by a sphere passing same sieve aperture (dSieve). In another non-limiting example, cube shaped particles having a length width and height of 5 m may be characterized by a sphere of identical maximum length (dmax).

[0039] In some embodiments, the batch fuel activation system 102 comprises a piston 104 extending from a piston first end 106 to a piston second end 108. In some embodiments, the piston second end 108 passes through the piston longitudinal axis 142 and is substantially cylindrical in shape. In some embodiments, the piston second end 108 is straight along the piston longitudinal axis 142 extending from a piston first end 106 to a piston second end 108. In some embodiments, the piston 104 includes one or more bends, kinks, or curvatures (not shown) along the piston longitudinal axis 142. For example, the piston 104 may be angled relative to a longitudinal axis of the second interior cavity 120 and / or mixing chamber 116 such that the second interior cavity 120 and / or mixing chamber 116 form a biased angle with respect to the piston longitudinal axis 142. The biased angle may facilitate mixing of a plurality of fuel particles and an activating metal alloy by providing an additional axis of rotation within the mixing chamber 116 for mixing. For example, the biased angle may provide mixing of the plurality of fuel particles and catalyst side to side (i.e. along the longitudinal axis of the mixing chamber 116, instead of or in addition to mixing along the axis of rotation).

[0040] In some embodiments, the batch fuel activation system 102 comprises a heating chamber 110. In some embodiments, the heating chamber 110 has an exterior surface defining a first interior cavity 112. In some embodiments, the heating chamber 110 is substantially cylindrical in shape.

[0041] In some embodiments, the heating chamber 110 is configured to be heated to a desired temperature. For example, fluid such as air and / or an inert gas may be forced into at least one of the first interior cavity 112, the second interior cavity 120, and the third interior cavity 128 at a desired temperature. In some embodiments, the fluid forced into the first interior cavity 112, the second interior cavity 120, and the third interior cavity 128 is constantly pumped in at a rate equal to the rate at which the fluid exits the respective cavity. In another non-limiting example, a heating jacket may be disposed around the heating chamber 110, thereby heating the first interior cavity 112 and components therein. In another non-limiting example, batch fuel activation system 102 is configured to use heat from a waste stream to heat the heating chamber 110 and components therein.

[0042] In some embodiments, the heating chamber 110 is configured to maintain the desired temperature within the first interior cavity. In some embodiments, the desired temperature is between 20 °C to 200 °C, 25 °C to 200 °C, or 50 °C to 200 °C. In some embodiments, the desired temperature is between 20-30 °C, 30-40 °C, 40-50 °C, 50-60 °C, 60-70 °C, 70-80 °C, 80-90 °C, 90-100 °C, 100-110 °C, 110-120 °C, 120-130 °C, 130-140°C, 140-150 °C, 150-160 °C, 160-170 °C, 170-180 °C, 180-190 °C, or 190-200 °C. In some embodiments, the desired temperature is between 20-50 °C, 50-100 °C, 100-150 °C, or 150- 200 °C. In some embodiments, the desired temperature is between 50-100 °C or 100-200 °C. In some embodiments, the desired temperature is between 20-50 °C.

[0043] In some embodiments, an angling chamber 1 14 is disposed between the piston first end 106 and the piston second end 108. In some embodiments, the longitudinal axis of the angling chamber 114 is aligned coaxially with the longitudinal axis of the piston 104. In some embodiments, the longitudinal axis of the angling chamber 114 is offset from the longitudinal axis of the piston 104. For example, the longitudinal axis of the angling chamber 114 may be positioned from the longitudinal axis of the piston 104 by an angle between 0-5, 5-10, 10-15, 15-20, 20-25, 25-30, 30-35, 35-40, or 40-45 degrees. In some embodiments, the longitudinal axis of the angling chamber 114 may be positioned at an angle relative to the longitudinal axis of the piston 104 by an angle between 0-5, 5-10, 10- 15, 15-20, 20-25, 25-30, 30-35, 35-40, or 40-45 degrees. Tilting the angling chamber 114 or the mixing chamber relative to the rotational axis may facilitate mixing by providing two axes of rotation. In some embodiments, the angling chamber is configurable to transition from a first angle to a second angle.

[0044] In some embodiments, the piston 104 is coupled with an actuator (not shown) configured to rotate the piston about the longitudinal axis of the piston 104. In some embodiments, the piston 104 is configured to rotate at a speed between 2-30 rotations per minute. In some embodiments, the piston 104 is configured to rotate at a speed between 2-5, 5-10, 10-15, 15-20, 20-25, or 25-30 rotations per minute. In some embodiments, the piston 104 is configured to rotate at a speed between 2-10, 10-20, or 20-30 rotations per minute. In some embodiments, the piston 104 is configured to rotate about piston second end 108.

[0045] In some embodiments, the piston 104 passes through at least one of the heating chamber 110, the angling chamber 114, the mixing chamber 116, or any combination of chambers thereof. In some embodiments, the piston first end 106 of the piston 104 passes at least partially through one end of the heating chamber 110 and the piston second end 108 passes at least partially through a second end opposite to and spaced apart from the first end of the heating chamber 110. In some embodiments, an end of the piston 104 is coupled with an end of the angling chamber 114. In some embodiments, the piston 104 forms two segments, each segment spaced apart by the angling chamber 114 and having coaxial longitudinal axes.

[0046] In some embodiments, the angling chamber 114 has a substantially cylindrical shape. In some embodiments, the angling chamber 114 has an outer surface 118 defining a second interior cavity 120. In some embodiments, the second interior cavity 120 of the angling chamber 114 is the same shape as the outer surface 118 of the angling chamber 114. In some embodiments, the outer surface 118 of the angling chamber 114 is substantially cylindrical and the second interior cavity 120 of the angling chamber 114 is substantially cylindrical.

[0047] In some embodiments, the angling chamber 114 has one or more openings through the outer surface 118 of the angling chamber 114. For example, the outer surface 118 may comprise a mesh structure with a plurality of openings through the outer surface 118 of the angling chamber 114 and into the second interior cavity 120 of the angling chamber 114.

[0048] In some embodiments, a ramp 122 extends at least partially over an interior surface of the angling chamber 114 within the second interior cavity 120. In some embodiments, the ramp 122 extends along the longitudinal axis of the angling chamber 114 from a first end 124 to a second end 126. For example, the ramp 122 may extend over at least 25%, 50%, 75%, or 100% of the length of the angling chamber 114. In some embodiments, the ramp 122 extends from the interior surface of the second interior cavity 120 by an offset distance. In some embodiments, the ramp 122 has a tapered surface 144 forming an angle greater than zero degrees relative to piston longitudinal axis 142. In some embodiments, the ramp 122 is disposed at an angle greater than zero relative to the piston longitudinal axis 142. In some embodiments, the tapered surface 144 of the ramp 122 forms an angle with the piston longitudinal axis 142 by an angle between 0-5, 5-10, 10-15, 15-20, 20-25, 25-30, 30-35, 35- 40, or 40-45 degrees.

[0049] In some embodiments, the piston 104 extends at least partially through the second interior cavity 120 along the piston longitudinal axis 142. In some embodiments, the ramp 122 extends radially from an outer surface of the piston 104. In some embodiments, the ramp 122 has tapered surface 144 forming an angle greater than zero degrees relative to the piston longitudinal axis 142. In some embodiments, the ramp 122 forms an angle with the piston longitudinal axis 142 by an angle between 0-5, 5-10, 10-15, 15-20, 20-25, 25-30, 30- 35, 35-40, or 40-45 degrees. In some embodiments, the mixing chamber 116 is coupled to the tapered surface 144. The angle formed between the mixing chamber axis of symmetry 140 and piston longitudinal axis 142 (i.e. the axis of rotation) may provide enhanced mixing between the plurality of fuel particles and the activating metal alloys relative to rotation of amixing chamber axis of symmetry 140 with no angle formed between the mixing chamber axis of symmetry 140 and the piston longitudinal axis 142.

[0050] In some embodiments, the third interior cavity 128 comprises a mixing chamber inlet 132 configured to sealably receive a plurality of fuel particles and a catalyst. In some embodiments, the mixing chamber inlet 132 comprises a seal 130. For example, the seal 130 may be an O-ring, a membrane, a diaphragm, or a sealable valve. In some embodiments, an inlet axis passes through the center of the inlet. In some embodiments, the inlet axis forms an angle greater than zero with the piston longitudinal axis 142. For example, the angle may be between 0-5, 5-10, 10-15, 15-20, 20-25, 25-30, 30-35, 35-40, or 40-45 degrees. In some embodiments, an inlet axis passes through the center of the inlet. In some embodiments, the inlet axis forms an angle greater than zero with the interior surface of the second interior cavity 120. For example, the angle may be between 0-5, 5-10, 10-15, 15-20, 20-25, 25-30, 30-35, 35-40, or 40-45 degrees. In some embodiments, the inlet axis forms an angle greater than zero with the tapered surface 144 of the ramp 122. For example, the angle may be between 0-5, 5-10, 10-15, 15-20, 20-25, 25-30, 30-35, 35-40, or 40-45 degrees.

[0051] In some embodiments, a mixing chamber axis of symmetry 140 passes through the symmetric axis of the mixing chamber 116. In some embodiments, the mixing chamber axis of symmetry 140 is the same as the inlet axis. In some embodiments, the mixing chamber axis of symmetry 140 is offset from the inlet axis by a distance greater than zero. In some embodiments, the mixing chamber axis of symmetry 140 forms an angle greater than zero with the piston longitudinal axis 142. For example, the angle may be between 0-5, 5-10, 10- 15, 15-20, 20-25, 25-30, 30-35, 35-40, or 40-45 degrees. In some embodiments, the mixing chamber axis of symmetry 140 forms an angle greater than zero with the interior surface of the second interior cavity 120. For example, the angle may be between 0-5, 5-10, 10-15, 15- 20, 20-25, 25-30, 30-35, 35-40, or 40-45 degrees. In some embodiments, the mixing chamber axis of symmetry 140 forms an angle greater than zero with the interior surface of the tapered surface 144 of the ramp 122. For example, the angle may be between 0-5, 5-10, 10-15, 15-20, 20-25, 25-30, 30-35, 35-40, or 40-45 degrees.

[0052] In some embodiments, one or more baffles (not shown) extend radially from the interior surface of the third interior cavity 128 towards the mixing chamber axis of symmetry 140. In some embodiments, the one or more baffles extend along a portion of the length of the third interior cavity 128 interior surface and towards the mixing chamber axis of symmetry 140. In some embodiments, the one or more baffles extend along the entire length of the third interior cavity 128 interior surface and towards the mixing chamber axisof symmetry 140. In some embodiments, the third interior cavity 128 retains two or more baffles, wherein the two or baffles extend at least partially along the length of the third interior cavity 128 and are spaced radially symmetrically relative to the mixing chamber axis of symmetry 140.

[0053] In some embodiments, the one or more baffles extend at least partially circumferentially along the second interior cavity 120 interior surface and towards the mixing chamber axis of symmetry 140. In some embodiments, the one or more baffles extend circumferentially around the second interior cavity 120 interior surface and towards the mixing chamber axis of symmetry 140. In some embodiments, the third interior cavity 128 retains two or more baffles, wherein the two or baffles extend at least partially along the length of the third interior cavity 128 and are spaced apart from one another by a distance greater than zero and extend radially towards the mixing chamber axis of symmetry 140. In some embodiments, each circumferential baffle is spaced apart from and equidistant relative to each neighboring circumferential baffle, thereby spacing the baffles evenly along the mixing chamber axis of symmetry 140.

[0054] In some embodiments, a rod (not shown) extends at least partially through the mixing chamber axis of symmetry 140 within the mixing chamber 116. In some embodiments, a paddle, an impeller, a fork, a whisk, a screw, or any combination thereof extend from a distal end of the rod within the mixing chamber 116. In some embodiments, the one or more baffles extend along at least a portion of the length of the exterior surface of the rod and towards the interior surface of the third interior cavity 128. In some embodiments, the one or more baffles extend around at least a portion of the circumference of the exterior surface of the rod and towards the interior surface of the third interior cavity 128.

[0055] In some embodiments, one or more baffles is selected from a group consisting of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, or greater than 30 baffles. In some embodiments, the one or more baffles are angled relative to their respective attachment surface. For example, the one or more baffles may be angled at an inclination greater than zero in a direction parallel to an axis of rotation. In another example, the one or more baffles may be angled at an inclination greater than zero in a direction perpendicular to an axis of rotation. In some embodiments, the one or more baffles are collapsible and / or foldable. For example, the one or more baffles may define an inflatable fluid bladder thereby enabling the one or more baffles to be reversibly inflated and deflated. In some embodiments, the one or more baffles are removably coupled to theirrespective attachment surfaces. In some embodiments, the interior of the third interior cavity 128 and / or the exterior of the rod is configurable with a plurality of attachment points such that the one or more baffles may be coupled to a first location, decoupled from the first location, and coupled to a second location spaced apart from the first location.

[0056] The one or more baffles may further facilitate mixing of the plurality of fuel particles and the activating metal alloy in the third interior cavity 128. In some embodiments, the one or more baffles are configured to deflect and / or disturb radial aggregation of a portion of the plurality of fuel particles around the interior of the third interior cavity 128 and / or rod thereby increasing mixing within the third interior cavity 128. In some embodiments, the one or more baffles are configured to prevent aggregation, localization, and / or agglomeration of a portion of the plurality of fuel particles at the interior surface of the third interior cavity 128. In some embodiments, the one or more baffles are configured to prevent the formation of regions within the third interior cavity 128 where a portion of the plurality of fuel particles becomes trapped, immobile, and where little to no mixing occurs (i.e., a dead zone). For example, the baffles may be configured to facilitate mixing in a direction along the longitudinal axis of the mixing chamber 116, optionally in addition to rotational mixing circumferentially about the longitudinal axis of the mixing chamber 116.

[0057] In some embodiments, mixing chamber 116 is configured to be sealably filled with an inert gas. In some embodiments, the inert gas is argon. In some embodiments, the inert gas is selected from a group consisting of argon, krypton, xenon, helium, neon, radon, oganesson, air, and a combination of any two or more thereof. In some embodiments, the plurality of fuel particles comprise aluminum.

[0058] In some embodiments, an inner surface of the third interior cavity comprises an abrasive coating configured to induce surface abrasion of the plurality of fuel particles. For example, this may facilitate further activation of the fuel particles by increasing the surface area of each individual particle and therefore increase the exposure of the particle to the catalyst.

[0059] In some embodiments, a method for activation of the plurality of fuel particles is described herein. In some embodiments, the method comprises receiving the batch fuel activation system 102, introducing the plurality of fuel particles through the sealable port of the mixing chamber 116 and into the third interior cavity 128. The catalyst is introduced through the sealable port of the mixing chamber 116 and into the third interior cavity 128. The sealable port of the mixing chamber 116 is then sealed and the piston 104 beginsrotating about the longitudinal axis of the piston 104, thereby rotating the mixing chamber 116 at an angle relative to the longitudinal axis of the piston 104 and mixing the plurality of the fuel particles with the catalyst.

[0060] FIG. 2A illustrates a second embodiment of a batch fuel activation system 202 according to embodiments described herein. In some embodiments, the batch fuel activation system 202 comprises a heating chamber 204 and a mixing chamber 206 disposed within the heating chamber 204. In some embodiments, the heating chamber 204 has a first door 208 and a second door 210 configured to open and close and provide access to the interior of the heating chamber 204. In some embodiments, the first door 208 is configured to have a first locking mechanism 212. In some embodiments, the second door 210 is configured to have a second locking mechanism 214. In some embodiments, the first locking mechanism 212 and second locking mechanism 214 are latches. In some embodiments, the first locking mechanism 212, the second locking mechanism 214, or both the first locking mechanism 212 and the second locking mechanism 214 comprises at least one of: bayonet coupling, screw coupling, push-pull coupling, plug-and-socket coupling, breakaway coupling, push- and-press-to-release coupling, coupling locked by screw, push-push locked coupling, magnetic coupling, electro-magnet, magnet, attachable mechanism, detachable mechanism, linking mechanism, binding mechanism, coupling, connector, mechanical holder, suction feature, suction cup, peg, clip, staple, ring, pin, hook, loop, snap-lock hook, snap-on hook, bracket, hanger, mount, chain, track-and-trolley, screw, nut-and-screw, nut-and-bolt, velcro, hook-and-loop, adhesive, pressure sensitive adhesive (PSA), self-adhesive tape, adhesive tape, double-side adhesive tape, sticky tape, weight, friction, fastener, dual-lock fastener, self-mating fastener, reclosable fastener, and another locking mechanism.

[0061] In some embodiments, an interior frame 216 is disposed within the heating chamber 204. In some embodiments, the interior frame 216 is fixedly attached to the interior of the heating chamber 204. In some embodiments, the interior frame 216 is configured to have wheels attached. In some embodiments, the mixing chamber 206 is disposed on the interior frame 216. For example, the mixing chamber 206 may be configured to rest on wheels attached to the interior frame 216, or may be configured with grooves running along the outside of the mixing chamber 206 that align with the wheels.

[0062] In some embodiments, a piston 218 extends through the heating chamber 204. In some embodiments, the mixing chamber piston 218 extends only a portion of the way through the heating chamber 204. In some embodiments, the piston 218 extends through the entirety of the heating chamber 204. In some embodiments, the piston 218 is attached to anactuator 220. In some embodiments, the actuator 220 is mounted on the exterior of the heating chamber 204. In some embodiments, the actuator 220 rotates the piston 218. In some embodiments, the actuator 220 rotates the piston 218 at a set rate. For example, the actuator 220 may rotate the piston 218 at a rate of 2 to 30 revolutions per minute, 2-5 rpm, 5-10 rpm, 10-15 rpm, 15-20 rpm, 20-25 rpm, or 25-30 rpm.

[0063] In some embodiments, a control panel 222 is configured to be mounted on the exterior of the heating chamber 204. In some embodiments, the control panel 222 controls the desired temperature of the heating chamber 204. In some embodiments, the control panel 222 controls the rate of rotation of the actuator 220 and piston 218.

[0064] In some embodiments, the batch fuel activation system 202 is coupled with a frame 224. In some embodiments, the frame 224 is configured to elevate the batch fuel activation system 202 a distance off of the ground. In some embodiments, the batch fuel activation system 202 is fixedly attached to the frame 224. In some embodiments, the batch fuel activation system 202 abuts a portion of the frame 224 and is configured to freely rotate about the longitudinal axis of the piston while maintaining at least partial contact with the frame 224.

[0065] In some embodiments, the heating chamber 204 is configured to maintain the desired temperature within the heating chamber. In some embodiments, the heating chamber 204 is heated in the same manner described with respect to the heating chamber 110 in FIG. 1. In some embodiments, the desired temperature is between 20 °C to 200 °C, 25 °C to 200 °C, or 50 °C to 200 °C. In some embodiments, the desired temperature is between 20-30 °C, 30-40 °C, 40-50 °C, 50-60 °C, 60-70 °C, 70-80 °C, 80-90 °C, 90-100 °C, 100-110 °C, 110- 120 °C, 120-130 °C, 130-140 °C, 140-150 °C, 150-160 °C, 160-170 °C, 170-180 °C, 180- 190 °C, or 190-200 °C. In some embodiments, the desired temperature is between 50-100 °C, 100-150 °C, or 150-200 °C. In some embodiments, the desired temperature is between 50-100 °C or 100-200 °C. In some embodiments, the desired temperature is between 20-50 °C.

[0066] In some embodiments, one or more baffles extends radially from the interior surface of the mixing chamber 206. For example, the baffles may further facilitate mixing of the plurality of fuel particles with the catalyst.

[0067] In some embodiments, the mixing chamber 206 is configured to be sealably filled with an inert gas. In some embodiments, the inert gas is argon. In some embodiments, the inert gas is selected from a group consisting of argon, krypton, xenon, helium, neon, radon,oganesson, air, and a combination of any two or more thereof. In some embodiments, the plurality of fuel particles comprise aluminum.

[0068] In some embodiments, an inner surface of the interior surface of the mixing chamber 206 comprises an abrasive coating configured to induce surface abrasion of the plurality of fuel particles. For example, this may facilitate further activation of the fuel particles by increasing the surface area of each particle and therefore the exposure to the activating metal alloy.

[0069] In some embodiments, a method for activation of the plurality of fuel particles is used. In some embodiments, the method comprises setting up the batch fuel activation system 202 and introducing the plurality of fuel particles and the catalyst into the interior cavity of the mixing chamber 206. The piston 218 is then rotated by the actuator 220 to cause the piston 218 to rotate about the longitudinal axis of the piston 218, thereby rotating at least one of the heating chamber 204 and mixing chamber 206.

[0070] FIG. 2B illustrates an example of the rotation system 244 according to embodiments described herein. In some embodiments, the rotation system 244 comprises an interior frame 216 coupled with a first wheel 226 and a second wheel 228. In some embodiments, the first wheel 226 and the second wheel 228 are coupled with the piston 218. In some embodiments, the first wheel 226 and second wheel 228 are spaced apart and offset from one another. In some embodiments, the first wheel 226 and second wheel 228 are spaced apart and in line with one another. In some embodiments, the first wheel 226 and second wheel 228 are configured to rotate with the rotation of the piston 218. In some embodiments, the first wheel 226 and / or the second wheel 228 is in contact with the mixing chamber 206. In some embodiments, the first wheel 226 and / or the second wheel 228 is configured to rotate the mixing chamber 206 when the first wheel 226 and / or the second wheel 228 are rotated.

[0071] In some embodiments, a third wheel 230 and a fourth wheel 232 are coupled with the interior frame 216. In some embodiments, the third wheel 230 and fourth wheel 232 are spaced apart from one another. In some embodiments, the third wheel 230 and fourth wheel 232 are spaced apart from the first wheel 226 and second wheel 228. In some embodiments, the third wheel 230 and fourth wheel 232 are configured to rotate circumferentially when in contact with a rotating mixing chamber 206. In some embodiments, the first wheel 226, second wheel 228, third wheel 230, and fourth wheel 232 are configured to slide along the interior frame 216 to an adjustable location.

[0072] In some embodiments, the heating chamber 204, the mixing chamber 206, or both the heating chamber 204 and the mixing chamber 206 are configured to be rotated using a rotating belt coupled to the respective chamber. In some embodiments, the heating chamber 204, the mixing chamber 206, or both the heating chamber 204 and the mixing chamber 206 are configured to be rotated using a track system coupled to the interior frame 216 and corresponding to one or more grooves disposed in the respective heating chamber 204, the mixing chamber 206, or both the heating chamber 204 and the mixing chamber 206.

[0073] FIG. 2C illustrates an embodiment of the actuator 220 according to embodiments described herein. In some embodiments, the actuator 220 comprises a motor 234 coupled to a gearbox 236. In some embodiments, the motor 234 and the gearbox 236 are coupled to a mount 238. In some embodiments, a coupling 240 is disposed within the mount 238. In some embodiments, the coupling 240 comprises a spider gear. In some embodiments, the coupling 240 couples the piston 218 and the motor 234 to rotate the piston 218 about the longitudinal axis of the piston 218 when the motor 234 is running.EQUIVALENTS AND SCOPE

[0074] In the claims articles such as "a," "an," and "the" may mean one or more than one unless indicated to the contrary or otherwise evident from the context. Claims or descriptions that include "or" between one or more members of a group are considered satisfied if one, more than one, or all of the group members are present in, employed in, or otherwise relevant to a given product or process unless indicated to the contrary or otherwise evident from the context. Provide herein are embodiments in which exactly one member of the group is present in, employed in, or otherwise relevant to a given product or process. Provided herein are embodiments in which more than one, or all of the group members are present in, employed in, or otherwise relevant to a given product or process.

[0075] In the appended claims, the terms "including" and "in which" are used as the plain- English equivalents of the respective terms "comprising" and "wherein," respectively. Moreover, the terms "first," "second," "third," and so forth, are used merely as labels and are not intended to impose numerical requirements on their objects.

[0076] The foregoing description of examples has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the present disclosure be limited not by this detailed description, but rather by the claims appended hereto. Future filed applications claiming priority to this application may claim the disclosed subject matter in adifferent manner and may generally include any set of one or more limitations as variously disclosed or otherwise demonstrated herein.

[0077] Furthermore, the inventions provided herein encompass all variations, combinations, and permutations in which one or more limitations, elements, clauses, and descriptive terms from one or more of the listed claims is introduced into another claim. For example, any claim that is dependent on another claim can be modified to include one or more limitations found in any other claim that is dependent on the same base claim. Where elements are presented as lists, e.g., in Markush group format, each subgroup of the elements is also disclosed, and any element(s) can be removed from the group. It should be understood that, in general, where the inventions provided and described herein, or aspects of the inventions described and provided herein, is / are referred to as comprising particular elements and / or features, certain embodiments of the inventions or aspects of the inventions consist, or consist essentially of, such elements and / or features. For purposes of simplicity, those embodiments have not been specifically set forth in haec verba herein. It is also noted that the terms "comprising" and "containing" are intended to be open and permits the inclusion of additional elements or steps. Where ranges are given, endpoints are included. Furthermore, unless otherwise indicated or otherwise evident from the context and understanding of one of ordinary skill in the art, values that are expressed as ranges can assume any specific value or sub-range within the stated ranges in different embodiments of the inventions described and provided herein, to the tenth of the unit of the lower limit of the range, unless the context clearly dictates otherwise.

[0078] This application refers to various issued patents, published patent applications, journal articles, and other publications, all of which are incorporated herein by reference. If there is a conflict between any of the incorporated references and the instant specification, the specification shall control. In addition, any particular embodiment that falls within the prior art may be explicitly excluded from any one or more of the claims. Because such embodiments are deemed to be known to one of ordinary skill in the art, they may be excluded even if the exclusion is not set forth explicitly herein. Any particular embodiment can be excluded from any claim, for any reason, whether or not related to the existence of prior art.

[0079] Each numerical value presented herein is contemplated to represent a minimum value or a maximum value in a range for a corresponding parameter. Accordingly, when added to the claims, the numerical value provides express support for claiming the range, which may lie above or below the numerical value, in accordance with the teachings herein.Every value between the minimum value and the maximum value within each numerical range presented herein (including any minimum, nominal, and maximum values shown in any tables), is contemplated and expressly supported herein, subject to the number of significant digits expressed in each particular range. The application expressly contemplates the ranges between the minimum and nominal values, nominal and maximum values, and minimum and maximum values.

[0080] Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation many equivalents to the specific embodiments described herein. The scope of the present embodiments described herein is not intended to be limited to the above Description, but rather is as set forth in the appended claims. Those of ordinary skill in the art will appreciate that various changes and modifications to this description may be made without departing from the spirit or scope of the present inventions, as defined in the following claims.

Claims

CLAIMSWhat is claimed is:

1. A system for activating a plurality of fuel particles with an activating metal alloy, the system comprising: a heating chamber having a first interior cavity; a piston configured to rotate about a longitudinal axis of the piston; a second chamber having a second interior cavity defined by the interior surface of the second chamber, wherein the second chamber is disposed within the first cavity and coupled to the piston to rotate therewith, a ramp extending at least partially along the interior surface, the ramp having a tapered surface forming an angle greater than zero degrees relative to the longitudinal axis of the piston; and a mixing chamber having a third interior cavity, the mixing chamber disposed within the second interior cavity and coupled to the ramp, wherein the mixing chamber comprises a sealable port configured to receive the plurality of fuel particles and the activating metal alloy.

2. A system for activating a plurality of fuel particles with an activating metal alloy, the system comprising: a heating chamber having a first interior cavity; a piston configured to rotate about a longitudinal axis of the piston; a mixing chamber having a third interior cavity defined by the interior surface of the mixing chamber, wherein the mixing chamber is disposed within the first cavity and coupled to the piston to rotate therewith, wherein the mixing chamber is disposed at an angle greater than zero relative to the longitudinal axis of the piston, wherein the mixing chamber comprises a sealable port configured to receive the plurality of fuel particles and the activating metal alloy.

3. The system of claim 2, further comprising a second chamber disposed within the heating chamber having a second interior cavity configured to receive the mixing chamber.

4. The system of any one of claims 1 to 3, wherein the first interior cavity is configured to be heated to a desired temperature.

5. The system of claim 4, wherein the desired temperature is between 50° C to 200° C.

6. The system according to any one of claims 1 to 5, wherein the third interior cavity comprises one or more baffles extending along the longitudinal axis of the mixing chamber and extending outward from the third interior cavity surface towards the interior cavity.

7. The system of any one of claims 1 to 6, wherein the mixing chamber is configured to be sealably filled with an inert gas.

8. The system of claim 7, wherein the inert gas is argon.

9. The system of claim 7, wherein the inert gas is selected from a group consisting of argon, krypton, xenon, helium, neon, radon, oganesson, air, and a combination of any two or more thereof.

10. The system of any one of claims 1 to 9, wherein the plurality of fuel particles comprise aluminum.

11. The system of any one of claims 1 to 10, wherein the activating metal alloy is selected from a group consisting of gallium, indium, bismuth, tin, and a combination of any two or more thereof.

12. The system of any one of claims 1 to 11, wherein the piston is coupled to an actuator configured to rotate at least one of the heating chamber, the second chamber, the mixing chamber, or any combination thereof between 2-30 rotations per minute.

13. The system of any one of claims 1 to 12, wherein the second chamber comprises a mesh material.

14. The system of any one of claims 1-7 or 12-13, wherein an inner surface of the third interior cavity comprises an abrasive coating configured to induce surface abrasion of the plurality of fuel particles.

15. A method for activation of the plurality of fuel particles comprising: receiving the system of any one of claims 1 to 14; introducing the plurality of fuel particles through the sealable port of the mixing chamber and into the third interior cavity; introducing the activating metal alloy through the sealable port of the mixing chamber and into the third interior cavity; sealing the sealable port; androtating the piston about the longitudinal axis of the piston, thereby rotating the mixing chamber at the angle relative to the longitudinal axis of the piston and mixing the plurality of fuel particles with the activating metal alloy.

16. A system for activating a plurality of fuel particles, the system comprising: a heating chamber having a first interior cavity configured to be heated to a desired temperature; a mixing chamber having a second interior cavity, the mixing chamber disposed within the first interior cavity and configured to receive the plurality of fuel particles and an activating metal alloy; a piston coupled to the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber; and an actuator coupled to the piston, wherein the actuator is configured to rotate the piston about a longitudinal axis of the piston thereby mixing the plurality of fuel particles and an activating metal alloy.

17. The system of claim 16, further comprising a first wheel, belt, or track coupled with the piston, such that the first moveable element rotates about the longitudinal axis of the piston as the piston rotates, wherein the first wheel, belt, or track is configured to contact the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber and to rotate the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber.

18. The system of claim 17, further comprising a second wheel, belt, or track spaced apart from the first wheel, belt, or track and coupled with the piston such that the second wheel, belt, or track rotates about the longitudinal axis of the piston as the piston rotates, wherein the second wheel, belt, or track is configured to contact the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber and to rotate the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber.

19. The system of claim 18, further comprising a third wheel, belt, or track spaced apart from the first wheel, belt, or track and the second wheel, belt, or track, wherein the third wheel, belt, or track is configured to support, rotate with, and contact the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber.

20. The system of claim 19, further comprising a fourth wheel, belt, or track spaced apart from the first wheel, belt, or track, the second wheel, belt, or track, and third wheel, belt, ortrack, wherein the fourth wheel, belt, or track is configured to support, rotate with, and contact the heating chamber, the mixing chamber, or both the heating chamber and the mixing chamber.

21. The system of any one of claims 17 to 20, wherein at least one of the first wheel, belt, or track, the second wheel, belt, or track, the third wheel, belt, or track, and the fourth wheel, belt, or track comprises a wheel.

22. The system of any one of claims 17 to 21, wherein at least one of the first wheel, belt, or track, the second wheel, belt, or track, the third wheel, belt, or track, and the fourth wheel, belt, or track is fixedly attached to a frame mounted to an interior surface of the first interior cavity.

23. The system of any one of claims 17 to 22, further comprising a coupling configured to couple the actuator with the piston, thereby providing rotation to the piston when the actuator is engaged with the coupling.

24. The system of claim 23, wherein the coupling comprises a spider gear.

25. The system of any one of claims 16 to 24, wherein the first interior cavity is configured to be heated to a desired temperature.

26. The system of claim 25, wherein the desired temperature is between 20 °C to 200 °C, 25 °C to 200 °C, or 50° C to 200° C.

27. The system of any one of claims 16 to 26, wherein the plurality of fuel particles comprise aluminum.

28. The system of any one of claims 16 to 27, wherein the activating metal alloy comprises gallium, indium, bismuth, and / or tin.

29. The system of any one of claims 16 to 28, wherein the piston is configured to rotate at least one of the first moveable element, the second moveable element, or both thereby rotating the heating chamber, the mixing chamber, or both between 2-30 rotations per minute.

30. The system of any one of claims 16 to 29, wherein the mixing chamber comprises a mesh material.

31. The system of any one of claims 16 to 30, wherein the second interior cavity comprises one or more baffles extending along the longitudinal axis of the mixing chamber and extending outward from the second interior cavity surface towards the interior cavity.

32. The system of any one of claims 16 to 31, wherein the mixing chamber is configured to be sealably filled with an inert gas.

33. The system of claim 32, wherein the inert gas is argon.

34. The system of claim 32, wherein the inert gas is selected from a group consisting of argon, krypton, xenon, helium, neon, radon, oganesson, air, and a combination of any two or more thereof.

35. The system of any one of claims 16 to 34, wherein an inner surface of the second interior cavity comprises an abrasive coating configured to induce surface abrasion of the plurality of fuel particles.

36. A method for activation of the plurality of fuel particles comprising: setting up the system of any one of claims 16 to 35; introducing the plurality of fuel particles and the activating metal alloy into the second interior cavity; and rotating the piston with the actuator to cause the piston to rotate about the longitudinal axis of the piston thereby rotating at least one of the heating chamber and the mixing chamber.

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