Flame Spray Pyrolysis Rotating Flame Metal Oxide Synthesis
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Solution Overview
Problem
Existing processes for producing metal oxides by flame spray pyrolysis often result in incomplete conversion and low crystallinity of the desired metal oxide products, requiring additional heat treatment steps to achieve the desired properties.
Innovation Solution
A process involving flame spray pyrolysis with a reaction space containing double-walled internals that introduce gas or vapor through slots to rotate the flame, increasing the residence time and adjusting the flame's geometry, which enhances the conversion and crystallinity of metal oxides by modifying the reaction conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If flame spray pyrolysis is used to produce metal oxides, then the production process is established and can produce simple and complex metal oxides, but incomplete conversion of input material and low crystallinity occur
Solution Approach 1:
The patent introduces a rotating flame mechanism where a gas stream is introduced tangentially to create a rotating flame front. This dynamic rotation increases the residence time of droplets in the high-temperature zone and ensures more uniform heating, thereby improving conversion completeness and crystallinity without requiring additional heat treatment steps.
Solution Approach 2:
The patent adds a rotational dimension to the flame by introducing gas tangentially at an angle to the flame axis. This creates a three-dimensional rotating flame structure from a traditionally linear flame, increasing the effective reaction path length and residence time, which improves product quality and crystallinity.
2Manufacturing precision
If additional heat treatment steps are applied to achieve desired crystallinity, then the crystallinity of metal oxides is improved, but the process complexity and production time increase
Solution Approach 1:
The patent performs the crystallization action during the spray pyrolysis process itself by creating a rotating flame with extended residence time. The droplets are exposed to optimized thermal conditions in the rotating flame zone, achieving desired crystallinity in-situ before product removal, thereby eliminating the need for separate post-treatment heat processing steps.
3Manufacturing precision
If the residence time of droplets in the flame is increased, then the conversion and crystallinity are improved, but the production efficiency may be reduced
Solution Approach 1:
The rotating flame creates a continuous, stable high-temperature reaction zone where droplets are continuously processed. The rotation ensures consistent residence time and uniform heating throughout the flame volume, maintaining high production efficiency while achieving complete conversion and desired crystallinity through the extended and optimized thermal exposure.
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
This process allows for specific adjustment of metal oxide properties, including complete conversion and crystallinity, improving the quality of the produced metal oxide powders, such as those used in lithium ion batteries, by extending the residence time and altering the flame's structure.
Implementation Method 1
a stream of a solution containing at least one oxidizable or hydrolysable metal compound is atomized to afford an aerosol by means of an atomizer gas
Implementation Method 2
a flame obtained by ignition of a mixture of fuel gas and air
Implementation Method 3
where they are oxidized and/or hydrolysed to give metal oxides
Implementation Method 4
where they are oxidized and/or hydrolysed to give metal oxides
Implementation Method 5
the slot is arranged such that this gas or the vapour brings about a rotation of the flame
Implementation Method 6
the reaction stream is cooled
Data Source
AI summary
A process for producing a metal oxide powder by flame spray pyrolysis wherea) a stream of a solution containing at least one oxidizable or hydrolysable metal compound is atomized to afford an aerosol by means of an atomizer gas,b) this aerosol is brought to reaction in the reaction space of the reactor with a flame obtained by ignition of a mixture of fuel gas and air,c) the reaction stream is cooled andd) the solid product is subsequently removed from the reaction stream, whereine) the reaction space comprises one or more successive double-walled internals, wherein the wall of the double-walled internal facing the flame-conducting region of the reaction space comprises at least one slot through which a gas or vapour is introduced into the reaction space in which the flame is burning andf) the slot is arranged such that this gas or vapour brings about a rotation of the flame.