Continuous Coprecipitation of Cathode Precursors for High Sphericity
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Solution Overview
Problem
Existing batch-type apparatuses for manufacturing positive electrode active material precursors suffer from low productivity and reduced sphericity due to long reaction times and varying reaction volumes, limiting the efficiency and quality of the production process.
Innovation Solution
An apparatus and method involving a reaction unit with continuous coprecipitation and solid-liquid separation units, allowing for continuous discharge of filtrate and reintroduction of solids, which includes a first reactor for coprecipitation and a second reactor for solid-liquid separation, with controlled stirring and filtration, enabling continuous operation and improved sphericity and crystal orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch-type apparatuses are used for coprecipitation, then the reaction can be completed, but the productivity is very low and the sphericity of the precursor is reduced
Solution Approach 1:
The patent applies preliminary action by pre-mixing the metal salts solution and maintaining it ready for continuous feeding into the reactor. The apparatus is designed with a continuous operation system where materials are prepared in advance and fed continuously, eliminating the batch filling time and enabling sustained high-speed production without compromising precursor quality
Solution Approach 2:
The patent implements continuity of useful action through a continuous coprecipitation process where metal salts solution and alkaline solution are continuously fed into the reactor, and the precursor is continuously discharged. This eliminates idle time between batches and maintains constant production flow, significantly improving productivity while preserving precursor sphericity
2Quantity of substance
If batch-type apparatuses are used, then the reaction volume can be filled, but only about 10% of the reaction weight of the precursor can be obtained per RT
Solution Approach 1:
The continuous operation system allows the reactor to operate without interruption, continuously producing and discharging precursor. This converts the batch process into a continuous flow process, increasing the quantity of precursor produced per unit time from 10% per RT to a much higher continuous output rate
Solution Approach 2:
The patent employs dynamic control of the continuous process, adjusting flow rates and reaction parameters to optimize precursor production. The system dynamically balances the feeding rates of metal salts and alkaline solutions to maintain optimal reaction conditions throughout continuous operation, maximizing precursor yield
3Shape
If the reaction volume continuously changes in batch-type apparatuses, then the reaction can proceed, but the sphericity of the precursor is reduced
Solution Approach 1:
The continuous coprecipitation process maintains constant reaction volume and steady-state conditions throughout the reaction. This eliminates the volume fluctuations inherent in batch processes, ensuring uniform precursor formation and high sphericity while reducing the overall reaction time through continuous material turnover
Solution Approach 2:
The continuous feeding system pre-mixes and continuously supplies reactants at optimal ratios, ensuring uniform nucleation and growth conditions from the start. This preliminary preparation of the reaction system maintains consistent volume and conditions, producing spherical precursors with excellent morphology
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method significantly enhances productivity and achieves positive electrode active material precursors with uniform particle size and high sphericity, improving the physical properties and performance of the final product.
Implementation Method 1
a first stirring means (130) located at the center inside the first reactor and configured to stir the raw material introduced from the input pipe to perform a coprecipitation reaction
Implementation Method 2
a second stirring means (230) located at the center inside the second reactor and configured to stir the reaction product introduced from the first connection pipe
Implementation Method 3
The filtrate discharge section may comprise a filter member (221) disposed between the inner wall of the second reactor and the first partition wall
Data Source
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AI summary
The embodiments may include an apparatus and a method for manufacturing a positive electrode active material precursor. An apparatus for manufacturing a positive electrode active material precursor according to one embodiment may include: a reaction unit (100) comprising a first reactor (110), an input pipe (120) configured to supply a raw material into the first reactor, and a first stirring means (130) located at the center inside the first reactor and configured to stir the raw material introduced from the input pipe to perform a coprecipitation reaction; a first connection pipe (300) through which a reaction product generated in the first reactor is discharged; a solid-liquid separation unit (200) comprising a second reactor (210), a second stirring means (230) located at the center inside the second reactor and configured to stir the reaction product introduced from the first connection pipe, and a filtrate discharge section (220) located at an upper portion of the second reactor; and a control unit connected to the reaction unit and the solid-liquid separation unit and configured to control the reaction unit and the solid-liquid separation unit to operate continuously.