Continuous 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, an apparatus for continuously activating a plurality of fuel particles with an activating metal alloy is described. In some embodiments, the activation chamber comprising a first inlet, a second inlet, an outlet, and an exterior surface defining a cavity therein. In some embodiments, the first inlet, the second inlet, and the outlet are disposed through the exterior surface of the activation chamber and are configured to permit the plurality of fuel particles to enter the cavity. In some embodiments, a screw disposed at least partially within the cavity of the activation chamber and forms a helical path from the first inlet to the outlet to transport the plurality of fuel particles and the activating metal alloy from the first inlet to the outlet.

Description

CONTINUOUS ALUMINUM ACTIVATION DEVICES, SYSTEMS, AND METHODS OFUSE THEREOFBACKGROUND

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 672,936, 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, systems, methods, and devices for continuously activating a plurality of fuel particles with an activating metal alloy are described herein. In some embodiments, an apparatus for continuously activating a plurality of fuel particles with an activating metal alloy includes an activation chamber comprising a first inlet, a second inlet, an outlet, and an exterior surface defining a cavity therein, wherein the first inlet is disposed through the exterior surface and is configured to permit the plurality of fuel particles to enter the cavity, the second inlet is disposed through the exterior surface and is configured to dispose the activating metal alloy into the cavity, and the outlet is disposed through the exterior surface and is configured to exit a plurality of activated fuel particles from the cavity, and a screw disposed at least partially within thecavity of the activation chamber, the screw forming a helical path from the first inlet to the outlet for the plurality of fuel particles and the activating metal alloy which, when rotated, transports the plurality of fuel particles from the first inlet to the outlet. In some embodiments, the second inlet is configured to couple with a nozzle, and wherein the nozzle is configured to drip, spray, or otherwise dispose a liquid from the second inlet onto at least a portion of the plurality of fuel particles. In some embodiments, the liquid comprises an activating metal alloy comprising gallium, indium, bismuth, and / or tin. In some embodiments, a heating jacket is disposed at least partially around the exterior of the activation chamber, wherein the heating jacket is configured to heat and / or maintain the cavity of the activation chamber to 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 screw is configured to rotate between 2-30 rotations per minute. In some embodiments, the cavity of the activation 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 cavity of the activation chamber comprises an abrasive coating configured to induce surface abrasion of the plurality of fuel particles. In another aspect a system for continuously activating a plurality of fuel particles with an activating metal alloy is described herein. In some embodiments, the system comprises a storage receptacle, and the activation chamber apparatus described above. In some embodiments, the system further comprises a chute configured to provide fluid communication between the storage receptacle and the activation chamber. In some embodiments, the chute is configured to transport the plurality of fuel particles from the storage receptacle to the first inlet of the activation chamber apparatus. In some embodiments, the storage receptacle is a hopper. In another aspect, a method for continuous activation of the plurality of fuel particles is described herein. In some embodiments, the method includes setting up the apparatus described above. In some embodiments, the method includes introducing the plurality of fuel particles through the first inlet of the activation chamber and into the cavity, spraying the plurality of fuel particles introduced at least partially with the activating metal alloy, and allowing one or more byproducts of the mixing of the activating metal alloy with the plurality of fuel particles to exit the activation chamber though the first outlet, wherein the byproducts comprise at least one of inert aluminum and activated aluminum, wherein introducing the plurality of fuel particles and / or the activating metal alloy is based on a prescribed rate of inputs, based on a threshold activation yield of the byproducts, or based on a prescribedtime duration. In another aspect, a method for continuous activation of a plurality of fuel particles is described herein. In some embodiments, the method comprises the steps of providing an apparatus configured to activate a plurality of fuel particles with an activating metal alloy, the apparatus comprising an activation chamber, a first inlet, a second inlet, an outlet, and a screw configured to transport the plurality of fuel particles from the first inlet to the outlet, spraying the plurality of fuel particles with the activating metal alloy from the second inlet, and allowing one or more activated fuel particles to exit the reactor vessel though the outlet, wherein the plurality of fuel particles comprise at least one of inert aluminum and activated aluminum.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0006] FIG. 1 illustrates an example of a continuous fuel activation system, according to embodiments described herein.DETAILED DESCRIPTION

[0007] 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.

[0008] To avoid these shortcomings, it is desirable to develop devices, systems, and methods of activating aluminum that are automated, scalable, rapid, and robust.

[0009] 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.

[0010] 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.

[0011] 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.

[0012] 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).

[0013] 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.

[0014] 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 but not 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 consisting of or comprising feedstock.

[0015] 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.

[0016] The term “room temperature” as used herein refers to 20 °C.

[0017] 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.

[0018] 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” canmean 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 also to be understood that all numbers and fractions thereof are presumed to be modified by the term “about.”

[0019] 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).

[0020] 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 someembodiments, all three percentiles are used to describe the size distribution of particles within a population.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

[0021] The devices, systems, and methods described herein are useful for activating aluminum using an activating metal alloy.

[0022] In some embodiments, the activating metal alloy comprises gallium and / or indium.

[0023] In some embodiments, the activating metal alloy is a eutectic mixture of gallium and indium (e.g., 80% gallium, 20% indium).

[0024] In some embodiments, the activating metal alloy further comprises tin and / or bismuth.

[0025] In some embodiments, the activating metal alloy is a non-eutectic alloy comprising bismuth, tin, indium, and gallium.

[0026] In some embodiments, the activating metal alloy comprises bismuth, tin, and indium and does not comprise gallium.Systems and Devices for Activating Aluminum

[0027] FIG. 1 illustrates an embodiment of a continuous fuel activation system 102 according to embodiments described herein. In some embodiments, the continuous fuel activation system 102 comprises an activation chamber 104 and a storage receptacle 106. The process as described herein may be a continuous process. The term “continuous” is generally understood by persons skilled in the present field of art of the present application to refer to a process that has a steady state of material added at a steady state to the cavity 108 and / or exiting the cavity 108 while the screw 110 is in rotation. As used herein, a “continuous process" refers to a process, or system or device configured to implement said process, where one or more process conditions are not 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 continuous process may include the steps of adding feedstock 112 or fuel particles at a defined flowrate or plurality of flowrates defined in a flowrate profile though a first inlet 114, rotating the screw 110, and exiting theactivated feedstock 112 and / or fuel particles at a defined flowrate or plurality of flowrates defined in a flowrate profile through a reactor outlet 116. As described herein, a continuous process for continuous fuel activation is the addition of fuel particles and removal of activated fuel particles from the activation chamber 104 when rotation of the screw 110 occurs.

[0028] 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 an 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.

[0029] 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.

[0030] 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 / orfeedstock into a formed shape. In some embodiments, the die is opened and the formed particle is released and / or removed.

[0031] 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.

[0032] 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.

[0033] The desired 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 through the same sieve aperture (dsieve), sphere of identical maximum length, a sphere of identical surface area (ds), a sphere of identical sedimentation rate (dseti). The type of characterization of particle size may be determined by a skilled in the art depending on how the particles are formed and there size. 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).

[0034] In some embodiments, the activation chamber 104 is substantially cylindrical in shape. In some embodiments, the activation chamber 104 is substantially rectangular, square, or any other shape which permits the rotation of a screw within an activation chamber 104 known to those skilled in the art. In some embodiments, the activation chamber 104 is hollow, having exterior walls defining an interior cavity 108.

[0035] In some embodiments, the activation chamber 104 is configured to be heated to a desired temperature. For example, fluid such as air and / or an inert gas may be forced into the cavity 108 at the desired temperature. In some embodiments, the fluid forced into thecavity 108 is constantly pumped in at a first defined flowrate equal to a second defined flowrate at which the fluid exits the respective cavity. In another non-limiting example, continuous fuel activation system 102 is configured to use heat and / or energy from a waste stream to activation chamber 104 and components therein.

[0036] In some embodiments, the activation chamber 104 is surrounded by a heated jacket 118. For example, the heated jacket 118 may extend at least partially along the longitudinal axis of the activation chamber 104, thereby at least partially surrounding the exterior surface of the activation chamber 104. In some embodiments, the activation chamber 104 comprises a third inlet (not shown) configured to pass a heated gas or liquid from a location exterior to the activation chamber 104 and into the cavity 108. In some embodiments, the activation chamber 104 comprises a second outlet (not shown) configured to exit the heated gas or liquid from the cavity 108 and to a location exterior to the activation chamber 104. In some embodiments, the activation chamber 104 is configured to maintain the desired temperature within the cavity 108. 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.

[0037] In some embodiments, the activation chamber 104 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.

[0038] In some embodiments, a screw 110 is disposed at least partially within the activation chamber 104. In some embodiments, the screw 110 is a threaded screw. In some embodiments, the screw 110 conveys a feedstock 112 through the activation chamber 104. In some embodiments, the screw 110 conveys the feedstock 112 from a first inlet 114 to a reactor outlet 116. In some embodiments, the first inlet 114 and reactor outlet 116 are on opposite sides of the activation chamber 104. In some embodiments, a first portion of the screw 110 is disposed exterior to the activation chamber 104 and a second portion of the screw 110 is located within the cavity 108 of the activation chamber 104. For example, thefirst portion of the screw located exterior to the cavity 108 may be coupled with an actuator located exterior to the activation chamber 104. In some embodiments, the screw 110 is sealably received in the cavity 108. In some embodiments, the screw 110 is coupled with an actuation (not shown) to rotate the screw 110 about a rotational axis 122 which is coaxial with the longitudinal axis of the screw 110.

[0039] In some embodiments, the screw 110 is configured to rotate at a speed between 2- 30 rotations per minute. In some embodiments, the screw 110 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 screw 110 is configured to rotate at a speed between 2-10, 10-20, or 20-30 rotations per minute. In some embodiments, the speed of the rotation of the screw 110 is selected based on one or more of the temperatures in the cavity 108, the average particle size and distribution of the plurality of fuel particles, the residence time, and / or the type of catalyst.

[0040] In some embodiments, the first inlet 114 and reactor outlet 116 are configured to go through the heated jacket 118 to enter the activation chamber 104. In some embodiments, a second inlet 124 is configured to go through the heated jacket 118 and enter the activation chamber 104. In some embodiments, the second inlet 124 is configured with a nozzle. In some embodiments, the nozzle sprays liquid onto the feedstock 112 and it is conveyed by the screw 110 through the activation chamber 104. In some embodiments, the liquid comprises an activating metal alloy.

[0041] In some embodiments, the storage receptacle 106 comprises a hopper inlet 120 and a hopper outlet 126. In some embodiments, the feedstock 112 is placed into the storage receptacle 106 through the hopper inlet 120 and exits through the hopper outlet 126 at a set rate. In some embodiments, the feedstock 112 is fed through the hopper outlet 126 by gravity. In some embodiments, the feedstock 112 is fed through the hopper outlet 126 by a conveyor belt. In some embodiments, the feedstock 112 is fed through the hopper outlet 126 by a conveying screw. In some embodiments, a chute 128 is attached to the hopper outlet 126 to guide the feedstock 112 to the first inlet 114.

[0042] In some embodiments, a method for continuous activation of the plurality of fuel particles is used. In some embodiments, the method comprises setting up continuous fuel activation system 102 and introducing the plurality of fuel particles through the first inlet 114 of the activation chamber 104 and into the cavity. The plurality of fuel particles is sprayed and introduced at least partially with the catalyst. One or more byproducts of the mixing of the catalyst with the plurality of fuel particles are then allowed to exit theactivation chamber 104 though the reactor outlet 116, wherein the byproducts comprise at least one of inert aluminum and activated aluminum. The introduction of the plurality of fuel particles and / or the catalyst is based on a prescribed rate of inputs, based on a threshold activation yield of the byproducts, or based on a prescribed time duration.

[0043] In some embodiments, at least a portion of the interior surface of the activation chamber 104 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 decreasing the thickness or removing oxide layer or other surface layers to enable catalyst access to the metallic aluminum underneath and / or increasing the surface area of each particle and therefore the exposure to the catalyst.

[0044] In some embodiments, a method for continuous activation of a plurality of fuel particles is used to activate the plurality of fuel particles with a catalyst. In some embodiments, the method includes providing the continuous fuel activation system 102 which is configured to activate the plurality of fuel particles with the catalyst through mixing. In some embodiments, the apparatus comprises an activation chamber 104, a first inlet 114, a second inlet 124, a reactor outlet 116, and a screw 110 configured to transport the plurality of fuel particles from the first inlet 114 to the reactor outlet 116.

[0045] In some embodiments, the method includes the step of coating the plurality of fuel particles with the catalyst. For example, the catalyst may be emitted from the second inlet 124 and passed through a nozzle configured to emit a spray of the catalyst. In some embodiments, the catalyst is emitted from the second inlet 124 and dripped onto the plurality of fuel particles. In some embodiments, the catalyst is emitted from the second inlet 124 as a powder and mixed with the plurality of fuel particles. In some embodiments, the method includes exiting a plurality of activated aluminum fuel particles 130 from the activation chamber 104.EQUIVALENTS AND SCOPE

[0046] 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 orprocess. 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.

[0047] 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.

[0048] 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 a different manner and may generally include any set of one or more limitations as variously disclosed or otherwise demonstrated herein.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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. An apparatus for continuously activating a plurality of fuel particles with an activating metal alloy, the apparatus comprising: an activation chamber comprising a first inlet, a second inlet, an outlet, and an exterior surface defining a cavity therein, wherein. the first inlet is disposed through the exterior surface and is configured to permit the plurality of fuel particles to enter the cavity, the second inlet is disposed through the exterior surface and is configured to dispose the activating metal alloy into the cavity, and the outlet is disposed through the exterior surface and is configured to exit a plurality of activated fuel particles from the cavity; and a screw disposed at least partially within the cavity of the activation chamber, the screw forming a helical path from the first inlet to the outlet for the plurality of fuel particles and the activating metal alloy which, when rotated, transports the plurality of fuel particles from the first inlet to the outlet.

2. The apparatus of claim 1, wherein the second inlet is configured to couple with a nozzle, and wherein the nozzle is configured to drip, spray, or otherwise dispose a liquid from the second inlet onto at least a portion of the plurality of fuel particles3. The apparatus of claim 1 or 2, wherein the liquid comprises a catalyst selected from a group consisting of gallium, indium, bismuth, tin, and a combination of any two or more thereof.

4. The apparatus of any one of claims 1 to 3, further comprising a heating jacket disposed at least partially around the exterior of the activation chamber, wherein the heating jacket is configured to heat and / or maintain the cavity of the activation chamber to a desired temperature.

5. The apparatus of claim 4, wherein the desired temperature is between 20 °C to 200 °C, 25 °C to 200 °C, or 50 °C to 200 °C.

6. The apparatus of any one of claims 1 to 5, wherein the screw is configured to rotate between 2-30 rotations per minute.

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

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

9. The apparatus 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 apparatus of any one of claims 1 to 9, wherein an inner surface of the cavity of the activation chamber comprises an abrasive coating configured to induce surface abrasion of the plurality of fuel particles.

11. A system for continuously activating a plurality of fuel particles with an activating metal alloy, the system comprising: a storage receptacle; and the activation chamber apparatus of any one of claims 1 to 10.

12. The system of claim 11, further comprising a chute configured to provide fluid communication between the storage receptacle and the activation chamber.

13. The system of claim 12, wherein the chute is configured to transport the plurality of fuel particles from the storage receptacle to the first inlet of the activation chamber apparatus.

14. The system of any one of claims 11 to 13, wherein the storage receptacle is a hopper.

15. A method for continuous activation of a plurality of fuel particles comprising: setting up the apparatus of any one of claims 1 to 10; introducing the plurality of fuel particles through the first inlet of the activation chamber and into the cavity; spraying the plurality of fuel particles introduced at least partially with the catalyst; and allowing one or more byproducts of the mixing of the catalyst with the plurality of fuel particles to exit the activation chamber though the first outlet, wherein the byproducts comprise at least one of inert aluminum and activated aluminum; wherein introducing the plurality of fuel particles and / or the catalyst is based on a prescribed rate of inputs, based on a threshold activation yield of the byproducts, or based on a prescribed time duration.

16. A method for continuous activation of a plurality of fuel particles comprising: providing an apparatus configured to activate a plurality of fuel particles with an activating metal alloy; the apparatus comprising an activation chamber, a first inlet, a second inlet, an outlet, and a screw configured to transport the plurality of fuel particles from the first inlet to the outlet; spraying the plurality of fuel particles with the catalyst from the second inlet; and allowing one or more activated fuel particles to exit the reactor vessel though the outlet, wherein the plurality of fuel particles comprise at least one of inert aluminum and activated aluminum.

Images