Mixed Metal Oxide Calcination via Controlled Precursor Particle Size
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Solution Overview
Problem
Current processes for producing lithium-containing mixed transition metal oxides, such as lithiated nickel cobalt aluminium oxides and lithiated nickel cobalt manganese oxides, require high energy consumption and long residence times in the calcination step, which is undesirable for improving throughput and reducing energy costs.
Innovation Solution
A process involving the provision of hydroxides or oxyhydroxides of nickel and at least one further transition metal, such as cobalt or manganese, with specific particle diameter ranges, subjected to a gas stream at temperatures between 150°C to 2000°C, allowing for efficient dehydration and formation of mixed metal oxides with low residual moisture, potentially reducing energy requirements and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional calcination is used to produce lithium-containing mixed transition metal oxides, then the desired oxide product is obtained, but energy consumption is high and residence time is long
Solution Approach 1:
The precursor is pre-prepared as a mixed hydroxide or oxyhydroxide with controlled particle size (D50: 0.1 μm to 5 mm) and specific composition ratios before calcination. This preliminary preparation optimizes the precursor structure to enable faster, more efficient calcination with reduced energy consumption and shorter residence times while maintaining high throughput production of the desired lithium-containing mixed transition metal oxide cathode materials
Solution Approach 2:
The invention optimizes multiple parameters including particle size distribution (D50: 0.1 μm to 5 mm), metal composition ratios (Ni: 0.5-0.95, Co: 0.025-0.4, Mn: 0-0.6, Al: 0-0.2), and calcination temperature to achieve the desired balance between productivity and energy efficiency. By controlling these parameters, the calcination process can be completed with reduced energy input and shorter time while maintaining high production rates
2Productivity
If pre-calcination is performed in a rotary kiln or roller hearth kiln to improve throughput, then production efficiency increases, but energy consumption increases and investment cost increases
Solution Approach 1:
The invention combines the precursor preparation and calcination steps into a single integrated process flow. By optimizing the precursor composition and particle size before calcination, the process achieves high throughput without requiring separate pre-calcination equipment such as rotary kilns or roller hearth kilns, thereby avoiding additional energy consumption and capital investment while maintaining improved production efficiency
3Productivity
If pre-calcination is performed in a rotary kiln or roller hearth kiln to improve throughput, then production efficiency increases, but investment cost increases due to extra equipment
Solution Approach 1:
The precursor is pre-prepared with optimized composition and particle size characteristics before entering the calcination step. This preliminary action eliminates the need for additional pre-calcination equipment, reducing capital investment and equipment complexity while achieving high throughput production of lithium-containing mixed transition metal oxides through a streamlined single-stage calcination process
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 enhances the energy efficiency by minimizing residence times and energy consumption, producing mixed metal oxides suitable for lithium ion battery cathode materials with improved performance characteristics.
Implementation Method 1
subjecting said hydroxide or oxyhydroxide of TM to a stream of gas with a temperature in the range of from 150 to 2000° C.
Implementation Method 2
allowing for efficient dehydration and formation of mixed metal oxides with low residual moisture
Data Source
AI summary
A process for making a mixed metal oxide, may involve: (a) providing a hydroxide or oxyhydroxide of TM with an average particle diameter (D50) in the range of from 0.1 μm to 5 mm; (b) subjecting the hydroxide or oxyhydroxide of TM to a stream of gas with a temperature in the range of from 150 to 2000° C., wherein TM contains nickel and at least one further transition metal selected from cobalt and manganese.