Apparatus and process for high throughput powder production
Apparatuses and processes for forming powder are disclosed. The apparatus includes a chamber having a head plate and an array of aerosol and burner nozzles attached to the head plate for generating aerosols and flames respectively. Powder is produced by atomizing a liquid composition to project an aerosol of droplets into the chamber and heating the aerosol with flames projected by the burner nozzles.
1. An apparatus for producing powder, the apparatus comprising:
a chamber having a head plate;
an array of nozzles attached to the head plate, wherein the array of nozzles includes at least four aerosol nozzle for introducing an aerosol of droplets into the chamber and at least two burner nozzles directly adjacent each aerosol nozzle for projecting flames into the chamber and wherein the aerosol and flames are oriented in the same general flow direction; and
an exit port connected to the chamber which allows produced powder to exit the chamber.
2. The apparatus of claim 1 , wherein the array of nozzles includes at least 6 aerosol nozzles, each of which are directly adjacent at least two burner nozzles.
3. The apparatus of claim 1 , wherein the array of nozzles includes at least 20 aerosol nozzles, each of which are directly adjacent at least two burner nozzles.
4. The apparatus of claim 1 , wherein the aerosol nozzles are aerosol pneumatic spray nozzles.
5. The apparatus of claim 1 , wherein the array of nozzles includes at least three burner nozzles directly adjacent each aerosol nozzles.
6. The apparatus of claim 1 , wherein each burner nozzle projects a flame in the shape of a spear.
7. The apparatus of claim 6 , wherein the aerosol nozzles are aerosol pneumatic spray nozzles.
8. The apparatus of claim 1 , wherein the apparatus has a production rate of greater than 1 kilogram per hour (kg/hr).
9. The apparatus of claim 1 , wherein the apparatus has a production rate of greater than about 10 kilogram per hour (kg/hr).
10. The apparatus of claim 1 , further comprising a collection system in fluid communication with the exit port to collect produced powder exiting the chamber.
11. A process of forming a powder, the process comprising:
atomizing a liquid composition to project an aerosol of droplets having a flow direction into a chamber through at least four aerosol nozzle wherein the chamber includes at least two burner nozzles that are directly adjacent each aerosol nozzle and that each project a flame that is adjacent the aerosol of droplets and oriented in the same general flow direction as the aerosol of droplets and wherein the liquid composition contains one or more dissolved or suspended precursors and the flames provide heat to convert the aerosol of droplets to a powder.
12. The process of claim 11 , wherein atomizing the liquid composition to project the aerosol of droplets is through at least 20 aerosol nozzles and wherein the chamber includes at least two burner nozzles that are directly adjacent each aerosol nozzle to project flames adjacent the aerosol of droplets.
13. The process of claim 11 , wherein the rate of atomizing the liquid composition is no less than about 1 liter per hour per aerosol nozzle.
14. The process of claim 11 , wherein aerosol nozzle or nozzles is or are a pneumatic spray nozzle or nozzles and wherein the at least two burner nozzles each project a flame in the shape of a spear.
15. The process of claim 11 , wherein the liquid composition contains precursors to form one or more active electrode powders and optionally one or more dopant precursors and optionally one or more carbon precursors.
16. The process of claim 15 , wherein the liquid composition contains precursors to form one or more active lithium metal or mixed metal phosphate powders.
17. The process of claim 16 , wherein the liquid composition further includes one or more carbon precursors that carbonizes to a substantially carbon containing material to mix with and/or coat the one or more active lithium metal or mixed metal phosphate powders.
18. The process of claim 15 , wherein the liquid composition contains a dopant precursor to dope the one or more active electrode powders.
19. The process of claim 15 , wherein one or more of the burner nozzles generates carbon that mixes with the aerosol of droplets and/or powder therefrom.
20. The process of claim 15 , further comprising forming an electrode from the one or more active electrode powders.
21. The process of claim 20 , further comprising forming a secondary battery with the electrode.