CA3202011A1 - Process for removing water from a particulate material - Google Patents
Process for removing water from a particulate materialInfo
- Publication number
- CA3202011A1 CA3202011A1 CA3202011A CA3202011A CA3202011A1 CA 3202011 A1 CA3202011 A1 CA 3202011A1 CA 3202011 A CA3202011 A CA 3202011A CA 3202011 A CA3202011 A CA 3202011A CA 3202011 A1 CA3202011 A1 CA 3202011A1
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- Canada
- Prior art keywords
- particulate material
- rotary kiln
- range
- process according
- nickel
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
- C01G53/00—Compounds of nickel
- C01G53/80—Compounds containing nickel, with or without oxygen or hydrogen, and containing one or more other elements
- C01G53/84—Hydroxides
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
- C01G53/00—Compounds of nickel
- C01G53/06—Carbonates
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F26—DRYING
- F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
- F26B17/00—Machines or apparatus for drying materials in loose, plastic, or fluidised form, e.g. granules, staple fibres, with progressive movement
- F26B17/12—Machines or apparatus for drying materials in loose, plastic, or fluidised form, e.g. granules, staple fibres, with progressive movement with movement performed solely by gravity, i.e. the material moving through a substantially vertical drying enclosure, e.g. shaft
- F26B17/14—Machines or apparatus for drying materials in loose, plastic, or fluidised form, e.g. granules, staple fibres, with progressive movement with movement performed solely by gravity, i.e. the material moving through a substantially vertical drying enclosure, e.g. shaft the materials moving through a counter-current of gas
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F26—DRYING
- F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
- F26B23/00—Heating arrangements
- F26B23/04—Heating arrangements using electric heating
- F26B23/06—Heating arrangements using electric heating resistance heating
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F26—DRYING
- F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
- F26B3/00—Drying solid materials or objects by processes involving the application of heat
- F26B3/02—Drying solid materials or objects by processes involving the application of heat by convection, i.e. heat being conveyed from a heat source to the materials or objects to be dried by a gas or vapour, e.g. air
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/36—Selection of substances as active materials, active masses, active liquids
- H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
- H01M4/52—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron
- H01M4/525—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2004/00—Particle morphology
- C01P2004/51—Particles with a specific particle size distribution
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2004/00—Particle morphology
- C01P2004/60—Particles characterised by their size
- C01P2004/61—Micrometer sized, i.e. from 1-100 micrometer
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M2004/026—Electrodes composed of, or comprising, active material characterised by the polarity
- H01M2004/028—Positive electrodes
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
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- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Inorganic Chemistry (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Microbiology (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Sustainable Development (AREA)
- Inorganic Compounds Of Heavy Metals (AREA)
- Manufacture And Refinement Of Metals (AREA)
- Battery Electrode And Active Subsutance (AREA)
- Solid-Sorbent Or Filter-Aiding Compositions (AREA)
- Removal Of Specific Substances (AREA)
Abstract
Process for removing water from a particulate material selected from (oxy)hydroxides and carbonates containing at least one of nickel or cobalt and at least one metal other than nickel, said process comprising the step of introducing at least one particulate material with a water content in the range of from 1 to 30 % by weight, referring to said particulate material, into a rotary kiln with external heating elements and moving it through the rotary kiln together with a flow of a gas, wherein the residual moisture of the resultant product is in the range of from 50 ppm to 1.5% by weight.
Description
Process for removing water from a particulate material The present invention is directed towards a process for removing water from a particulate mate-rial selected from (oxy)hydroxides and carbonates containing at least one of nickel or cobalt and at least one metal other than nickel, said process comprising the step of introducing at least one particulate material with a water content in the range of from 1 to 30 % by weight, referring to said particulate material, into a rotary kiln with external heating elements and moving it through the rotary kiln together with a flow of a gas, wherein the residual moisture of the resultant prod-uct is in the range of from 50 ppm to 1.5% by weight.
Water removal from particulate solid materials has been a topic of great interest. Drying of wet materials is a basic operation in pre-industrial as well as industrial process technology. Several challenges have to be met: In many cases, the morphology of said particulate materials needs to be preserved, and neither dusting nor lump nor ring formation is desired.
The heat transfer needs to be efficient: due to the high evaporation energy, a lot of energy has to be transferred to the wet material, and regardless of the way how the energy is generated, high energy losses are undesired.
In continuous processes, water removal offers even more challenges because in many continu-ous reactors, the reaction time is an average time. Both shortcuts and extremely long residence times of groups of particles need to be avoided due to incomplete reaction and undesired ag-glomeration of secondary particles, respectively.
In the manufacture of cathode active materials for lithium ion batteries, the topic of water re-moval has become of increased interest. Corresponding composite oxides are generally manu-factured by using a two-stage process. In a first stage, a sparingly soluble compound of the transition metal(s) is made by precipitating it from a solution, for example a carbonate or a hy-droxide. This sparingly soluble salt is in many cases also referred to as a precursor. Such pre-cursors are expected to meet tight specifications with regard to their particle size distribution and internal physical structure, characterized by e.g. their degree of sphericity or specific sur-face area (BET surface). In a second stage, said precursor is composite with a lithium com-pound, for example Li2CO3, LiOH or Li2O, and calcined at high temperatures, for example at 600 to 1100 C. Water removal thus is crucial between the two stages. A homogeneous precursor both in composition including water content, and morphology including particle size distribution is highly desired.
Water removal from particulate solid materials has been a topic of great interest. Drying of wet materials is a basic operation in pre-industrial as well as industrial process technology. Several challenges have to be met: In many cases, the morphology of said particulate materials needs to be preserved, and neither dusting nor lump nor ring formation is desired.
The heat transfer needs to be efficient: due to the high evaporation energy, a lot of energy has to be transferred to the wet material, and regardless of the way how the energy is generated, high energy losses are undesired.
In continuous processes, water removal offers even more challenges because in many continu-ous reactors, the reaction time is an average time. Both shortcuts and extremely long residence times of groups of particles need to be avoided due to incomplete reaction and undesired ag-glomeration of secondary particles, respectively.
In the manufacture of cathode active materials for lithium ion batteries, the topic of water re-moval has become of increased interest. Corresponding composite oxides are generally manu-factured by using a two-stage process. In a first stage, a sparingly soluble compound of the transition metal(s) is made by precipitating it from a solution, for example a carbonate or a hy-droxide. This sparingly soluble salt is in many cases also referred to as a precursor. Such pre-cursors are expected to meet tight specifications with regard to their particle size distribution and internal physical structure, characterized by e.g. their degree of sphericity or specific sur-face area (BET surface). In a second stage, said precursor is composite with a lithium com-pound, for example Li2CO3, LiOH or Li2O, and calcined at high temperatures, for example at 600 to 1100 C. Water removal thus is crucial between the two stages. A homogeneous precursor both in composition including water content, and morphology including particle size distribution is highly desired.
2 In many cases, after co-precipitation the precursor is separated from the mother liquor by solid-liquid separation methods, especially by filtration. The resulting filter cake may contain up to 30% by weight of water. A removal of said water requires a lot of energy. At the same time, it is desired to not negatively affect the morphology of the precursor.
It was therefore an objective of the present invention to provide a process by which water may be removed from particulate materials in an economic way, with the morphology of the particu-late material being preserved. It was further an objective to provide a reactor for performing such a process.
Accordingly, the process as defined at the outset has been found, hereinafter also referred to as "inventive process" or "process according to the present invention". The inventive process is a continuous process.
The inventive process starts off from a particulate material, also referred to as particulate solid, especially from a filter cake. Said particulate material introduced in the inventive process is wet.
This shall mean in the context of the present invention that the wet particulate material has a water content in the range of from 1 to 30% by weight. The water content may be determined by drying in vacuo at a temperature of 100 C until the weight is remaining unchanged. In the course of the inventive process, said wet particular material is introduced as a paste, a slurry or moist powder or an agglomerated moist powder. In a preferred embodiment, the wet particulate material is provided as a filter cake.
Said particulate material may have an average diameter (d50) in the range of from 1 pm to 1 mm, preferably 2 pm to 100 pm. The average diameter is advantageously determined by LA-SER diffraction, and in the context of the resent invention, it refers to the mass median value.
Said particulate material may have an irregular shape but in a preferred embodiment, said par-ticulate material has a regular shape, for example spheroidal or even spherical. The aspect ratio may be in the range of from 1 and 10, preferably from 1 to 3 and even more preferably from 1 to 1.1. The aspect ratio is defined as the ratio of width to length or specifically the particle diameter in the longest dimension versus the particle diameter in the shortest dimension. Perfectly spher-ical particles have an aspect ratio of 1.
In a preferred embodiment of the present invention, the wet particulate material is provided as a filter cake from a precipitation or preferably co-precipitation of a precursor for cathode active materials for lithium ion batteries. In such embodiments, said particulate solid preferably has an average particle diameter (dm) in the range of from 2 to 20 pm and even more preferably from 3
It was therefore an objective of the present invention to provide a process by which water may be removed from particulate materials in an economic way, with the morphology of the particu-late material being preserved. It was further an objective to provide a reactor for performing such a process.
Accordingly, the process as defined at the outset has been found, hereinafter also referred to as "inventive process" or "process according to the present invention". The inventive process is a continuous process.
The inventive process starts off from a particulate material, also referred to as particulate solid, especially from a filter cake. Said particulate material introduced in the inventive process is wet.
This shall mean in the context of the present invention that the wet particulate material has a water content in the range of from 1 to 30% by weight. The water content may be determined by drying in vacuo at a temperature of 100 C until the weight is remaining unchanged. In the course of the inventive process, said wet particular material is introduced as a paste, a slurry or moist powder or an agglomerated moist powder. In a preferred embodiment, the wet particulate material is provided as a filter cake.
Said particulate material may have an average diameter (d50) in the range of from 1 pm to 1 mm, preferably 2 pm to 100 pm. The average diameter is advantageously determined by LA-SER diffraction, and in the context of the resent invention, it refers to the mass median value.
Said particulate material may have an irregular shape but in a preferred embodiment, said par-ticulate material has a regular shape, for example spheroidal or even spherical. The aspect ratio may be in the range of from 1 and 10, preferably from 1 to 3 and even more preferably from 1 to 1.1. The aspect ratio is defined as the ratio of width to length or specifically the particle diameter in the longest dimension versus the particle diameter in the shortest dimension. Perfectly spher-ical particles have an aspect ratio of 1.
In a preferred embodiment of the present invention, the wet particulate material is provided as a filter cake from a precipitation or preferably co-precipitation of a precursor for cathode active materials for lithium ion batteries. In such embodiments, said particulate solid preferably has an average particle diameter (dm) in the range of from 2 to 20 pm and even more preferably from 3
3 to 15 pm. For example, the wet particulate material may be provided as a filter cake from a pre-cipitation of nickel hydroxide or cobalt hydroxide or from nickel carbonate or cobalt carbonate or from a co-precipitation.
The particulate material is selected from oxides, (oxy)hydroxides and carbonates of transition metals, preferred are carbonates and even more preferred are (oxy)hydroxides.
The term oxy-hydroxides does not only refer to compounds that contain the same stoichiometric share of ox-ide and hydroxide ions but also to non-stoichiometric compounds.
The particulate material is selected from (oxy)hydroxides and carbonates containing at least one transition metal selected from of nickel or cobalt and at least one metal other than nickel.
Thus, it may be cobalt oxyhydroxide or cobalt hydroxide or cobalt carbonate or a carbonate or (oxy)hydroxide of nickel that contains at least one metal other than nickel, for example manga-nese or cobalt.
In one embodiment of the present invention, said particulate material is selected from composite (oxy)hydroxides of nickel and at least one transition metal selected from cobalt and manganese and containing, optionally, at least one further metal selected from Mg, Al, Ba, Ti, Zr, Nb, Ta, W, Mo, Sb, and Y.
In one embodiment of the present invention, said particulate material is selected from composite carbonates of nickel and at least one transition metal selected from cobalt and manganese and containing, optionally, at least one further metal selected from Mg, Al, Ba, Ti, Zr, Nb, Ta, W, Mo, Sb, and Y, preferably from composite carbonates of nickel and manganese. In this context, car-bonates include basic carbonates, that are carbonates that contain some hydroxide or oxide counterions as well.
The wet particulate material may contain minor amounts of lithium, for example 1.5 to 3 mol-%
with respect to cobalt or the sum of nickel and cobalt and other transition metals present in said (oxy)hydroxide or carbonate, as the case may be.
In a preferred embodiment of the present invention, the wet particulate material is free from lith-ium. In this context, "free from lithium" refers to a lithium content of less than 1 mol-% referring to cobalt or the sum of nickel and cobalt and other transition metals present in said (oxy)hydroxide or carbonate, as the case may be.
The particulate material is selected from oxides, (oxy)hydroxides and carbonates of transition metals, preferred are carbonates and even more preferred are (oxy)hydroxides.
The term oxy-hydroxides does not only refer to compounds that contain the same stoichiometric share of ox-ide and hydroxide ions but also to non-stoichiometric compounds.
The particulate material is selected from (oxy)hydroxides and carbonates containing at least one transition metal selected from of nickel or cobalt and at least one metal other than nickel.
Thus, it may be cobalt oxyhydroxide or cobalt hydroxide or cobalt carbonate or a carbonate or (oxy)hydroxide of nickel that contains at least one metal other than nickel, for example manga-nese or cobalt.
In one embodiment of the present invention, said particulate material is selected from composite (oxy)hydroxides of nickel and at least one transition metal selected from cobalt and manganese and containing, optionally, at least one further metal selected from Mg, Al, Ba, Ti, Zr, Nb, Ta, W, Mo, Sb, and Y.
In one embodiment of the present invention, said particulate material is selected from composite carbonates of nickel and at least one transition metal selected from cobalt and manganese and containing, optionally, at least one further metal selected from Mg, Al, Ba, Ti, Zr, Nb, Ta, W, Mo, Sb, and Y, preferably from composite carbonates of nickel and manganese. In this context, car-bonates include basic carbonates, that are carbonates that contain some hydroxide or oxide counterions as well.
The wet particulate material may contain minor amounts of lithium, for example 1.5 to 3 mol-%
with respect to cobalt or the sum of nickel and cobalt and other transition metals present in said (oxy)hydroxide or carbonate, as the case may be.
In a preferred embodiment of the present invention, the wet particulate material is free from lith-ium. In this context, "free from lithium" refers to a lithium content of less than 1 mol-% referring to cobalt or the sum of nickel and cobalt and other transition metals present in said (oxy)hydroxide or carbonate, as the case may be.
4 Some elements are ubiquitous. In the context of the present invention, traces of ubiquitous met-als such as sodium, calcium, iron or zinc as impurities will not be taken into account in the de-scription of the present invention. Traces in this context will mean amounts of 0.02 mol-% or less, referring to the total metal content of the starting material. In addition, residual sulphate anions stemming from any sulphate starting material will be neglected as well.
In one embodiment of the present invention, the metal part of the mixed carbonate or mixed hydroxide of nickel and at least one transition metal selected from cobalt and manganese corre-sponds to general formula (I) NiaMlbMnc (I) where the variables are each defined as follows:
M1 is Co or a combination of Co and at least one metal selected from Ti, Zr, Al and Mg, a is in the range from 0.15 to 0.95, preferably from 0.6 to 0.92 or from 0.15 to 0.3 is in the range from zero to 0.35, preferably 0.05 to 0.2, is in the range from zero to 0.8, preferably 0.05 to 0.2, and a + b + c = 1.0 and at least one of b and c is greater than zero.
In one embodiment of the present invention, the average residence time of the particulate solid is in the range of from 30 minutes to 5 hours, preferably 1 to 3 hours. In this context, the aver-age residence time refers to the average residence time of the particulate material in the rotary kiln.
In one embodiment of the present invention, the wet particulate solid is introduced into the rota-ry kiln at ambient temperature. In another embodiment of the present invention, the wet particu-late solid is introduced into the rotary kiln at a temperature of from 50 C to 100 C.
In one embodiment of the present invention, the wet particulate solid is introduced into the rota-ry kiln by a chute or a vibrating chute, by a spiral conveyor or a screw conveyor, preferably by a screw conveyor with a single screw or multiple screws.
The wet particulate solid is then moved through the rotary kiln. Upon moving wet particulate solid the moisture content decreases. Preferably, at the end of the inventive process the residu-al moisture content is in the range of from 50 ppm to 1.5 % by weight, preferably 100 to 300 ppm by weight. The ppm are parts per million and refer to the weight. The residual moisture
In one embodiment of the present invention, the metal part of the mixed carbonate or mixed hydroxide of nickel and at least one transition metal selected from cobalt and manganese corre-sponds to general formula (I) NiaMlbMnc (I) where the variables are each defined as follows:
M1 is Co or a combination of Co and at least one metal selected from Ti, Zr, Al and Mg, a is in the range from 0.15 to 0.95, preferably from 0.6 to 0.92 or from 0.15 to 0.3 is in the range from zero to 0.35, preferably 0.05 to 0.2, is in the range from zero to 0.8, preferably 0.05 to 0.2, and a + b + c = 1.0 and at least one of b and c is greater than zero.
In one embodiment of the present invention, the average residence time of the particulate solid is in the range of from 30 minutes to 5 hours, preferably 1 to 3 hours. In this context, the aver-age residence time refers to the average residence time of the particulate material in the rotary kiln.
In one embodiment of the present invention, the wet particulate solid is introduced into the rota-ry kiln at ambient temperature. In another embodiment of the present invention, the wet particu-late solid is introduced into the rotary kiln at a temperature of from 50 C to 100 C.
In one embodiment of the present invention, the wet particulate solid is introduced into the rota-ry kiln by a chute or a vibrating chute, by a spiral conveyor or a screw conveyor, preferably by a screw conveyor with a single screw or multiple screws.
The wet particulate solid is then moved through the rotary kiln. Upon moving wet particulate solid the moisture content decreases. Preferably, at the end of the inventive process the residu-al moisture content is in the range of from 50 ppm to 1.5 % by weight, preferably 100 to 300 ppm by weight. The ppm are parts per million and refer to the weight. The residual moisture
5 content may be determined by Karl-Fischer titration or by thermo gravimetric methods.
In one embodiment of the present invention, the retort length of the rotary kiln is from one to 50 m, preferably from 5 to 25 meter.
In one embodiment of the present invention, the retort diameter of the rotary kiln is in the range of from 0.2 to 4 meter, preferably 1 to 2 meter.
In one embodiment of the present invention, the ratio retort length to retort diameter is in the range of from 5 to 50, preferably 10 to 25.
In one embodiment of the present invention, the rotary kiln is exactly horizontal. In another em-bodiment, the rotary kiln is tilted, for example with a tilt angle in the rage of from 0.2 to 7 , and the movement of the particulate solid through the rotary kiln is supported by gravitational force.
In one embodiment of the present invention, the rotary kiln is operated with 0.01 to 20 revolu-tions per minute, preferred are 0.5 to 5 revolutions per minute, and, in each case, continuously or in intervals. When operation in an interval mode is desired it is possible, for example, to stop the rotation after one to 5 revolutions for one to 60 minutes, and then to again perform 1 to 5 revolutions and again stop for 1 to 60 minutes, and so forth.
In one embodiment of the present invention, the rotary kiln may comprise internals. Internals may comprise multiple mechanicals units such as vertical baffles or dams, helical vanes, straight or inclined blades, L-lifters, plough shares, chain curtains or shovels. Internals may cover the entire cross section from the wall to the center of the rotary kiln or they may expand partially from the wall to center of the rotary kiln. Preferably, internals are arranged in sections of 0.2 to 5 m length along the axis of the rotary tube, each section comprising of 1 to 24 individ-ual mechanical units distributed regularly along the circumference of the rotary tube.
The rotary kiln has one or more external heating elements, for example an external furnace.
The heat from such external furnace my be generated through gas firing, electrical resistance heating, inductive heating, or micro-wave heating.
In one embodiment of the present invention, the retort length of the rotary kiln is from one to 50 m, preferably from 5 to 25 meter.
In one embodiment of the present invention, the retort diameter of the rotary kiln is in the range of from 0.2 to 4 meter, preferably 1 to 2 meter.
In one embodiment of the present invention, the ratio retort length to retort diameter is in the range of from 5 to 50, preferably 10 to 25.
In one embodiment of the present invention, the rotary kiln is exactly horizontal. In another em-bodiment, the rotary kiln is tilted, for example with a tilt angle in the rage of from 0.2 to 7 , and the movement of the particulate solid through the rotary kiln is supported by gravitational force.
In one embodiment of the present invention, the rotary kiln is operated with 0.01 to 20 revolu-tions per minute, preferred are 0.5 to 5 revolutions per minute, and, in each case, continuously or in intervals. When operation in an interval mode is desired it is possible, for example, to stop the rotation after one to 5 revolutions for one to 60 minutes, and then to again perform 1 to 5 revolutions and again stop for 1 to 60 minutes, and so forth.
In one embodiment of the present invention, the rotary kiln may comprise internals. Internals may comprise multiple mechanicals units such as vertical baffles or dams, helical vanes, straight or inclined blades, L-lifters, plough shares, chain curtains or shovels. Internals may cover the entire cross section from the wall to the center of the rotary kiln or they may expand partially from the wall to center of the rotary kiln. Preferably, internals are arranged in sections of 0.2 to 5 m length along the axis of the rotary tube, each section comprising of 1 to 24 individ-ual mechanical units distributed regularly along the circumference of the rotary tube.
The rotary kiln has one or more external heating elements, for example an external furnace.
The heat from such external furnace my be generated through gas firing, electrical resistance heating, inductive heating, or micro-wave heating.
6 Said particulate material is moved through the rotary kiln with a flow of gas.
Said gas may be air, an inert gas such as nitrogen, or oxygen-depleted air or oxygen-enriched air or flue gases.
air and flue gases are preferred.
In one embodiment of the present invention, the flow of gas has an inlet temperature in the range of from zero to 1400 C, preferred are 100 or 200 to 1000 C. In embodiments wherein the gas inlet temperature is 100 C or higher a preheating system is required. In embodiments wherein a preheating system is not desired the inlet temperature corresponds to ambient tem-perature.
In one embodiment of the present invention, said particulate material is moved through the rota-ry kiln with a co-current flow of gas. In another embodiment of the present invention, said flow of gas and said particulate solid are moved through the rotary kiln counter-currently. The co-current flow has the disadvantage that the almost finished precursor is in contact with gas corn-parably rich in humidity and carbon dioxide. This disadvantage is avoided if flow of gas and mo-tion of particulate solid are countercurrent.
In one embodiment of the present invention, on the discharge end of said rotary kiln, an inlet stream of inert gas, air, oxygen-enriched or oxygen-depleted air or flue gases are introduced into the rotary kiln.
In one embodiment of the present invention said rotary kiln has at least two distinguishable zones in which the particulate material is treated at different temperature levels, for example two to six temperature zones. The distinguishable zones are preset by the strongly endothermic process steps ¨ evaporation of water and chemical decomposition of hydroxide or carbonate as water or carbon dioxide or by applying different temperature levels via separate external heating zones.
In a preferred embodiment, in a first temperature zone the temperature of said particulate mate-rial is in the range of from 80 to 130 C and in a second temperature zone, the temperature is in the range of from 200 to 500 C, preferably 200 to 450 C, more preferably 220 to 300 C. Said temperature may be determined with a sensor.
By performing the inventive process, removal of water and, if applicable, of carbonate from par-ticulate materials may be performed in an economic way, with the morphology of the particulate material being preserved. In particular, by carrying out water evaporation and hydrox-ide/carbonate decomposition according to the inventive process reduces equipment footprint
Said gas may be air, an inert gas such as nitrogen, or oxygen-depleted air or oxygen-enriched air or flue gases.
air and flue gases are preferred.
In one embodiment of the present invention, the flow of gas has an inlet temperature in the range of from zero to 1400 C, preferred are 100 or 200 to 1000 C. In embodiments wherein the gas inlet temperature is 100 C or higher a preheating system is required. In embodiments wherein a preheating system is not desired the inlet temperature corresponds to ambient tem-perature.
In one embodiment of the present invention, said particulate material is moved through the rota-ry kiln with a co-current flow of gas. In another embodiment of the present invention, said flow of gas and said particulate solid are moved through the rotary kiln counter-currently. The co-current flow has the disadvantage that the almost finished precursor is in contact with gas corn-parably rich in humidity and carbon dioxide. This disadvantage is avoided if flow of gas and mo-tion of particulate solid are countercurrent.
In one embodiment of the present invention, on the discharge end of said rotary kiln, an inlet stream of inert gas, air, oxygen-enriched or oxygen-depleted air or flue gases are introduced into the rotary kiln.
In one embodiment of the present invention said rotary kiln has at least two distinguishable zones in which the particulate material is treated at different temperature levels, for example two to six temperature zones. The distinguishable zones are preset by the strongly endothermic process steps ¨ evaporation of water and chemical decomposition of hydroxide or carbonate as water or carbon dioxide or by applying different temperature levels via separate external heating zones.
In a preferred embodiment, in a first temperature zone the temperature of said particulate mate-rial is in the range of from 80 to 130 C and in a second temperature zone, the temperature is in the range of from 200 to 500 C, preferably 200 to 450 C, more preferably 220 to 300 C. Said temperature may be determined with a sensor.
By performing the inventive process, removal of water and, if applicable, of carbonate from par-ticulate materials may be performed in an economic way, with the morphology of the particulate material being preserved. In particular, by carrying out water evaporation and hydrox-ide/carbonate decomposition according to the inventive process reduces equipment footprint
7 and complexity as well as it improves the overall energy efficiency due to more efficient use of the sensible heat of the materials as well as reducing heat losses.
The invention is further illustrated by the following working examples.
General: dio, dal and d90 refer to the particle diameters at 10, 50 and 90 %
of the cumulative volume distribution).
I. Co-precipitation of a precursor A continuous stirred tank reactor was filled with deionized water and 49 g of ammonium sulfate per kg of water. The solution was tempered to 55 C and a pH value of 12 was adjusted by add-ing an aqueous sodium hydroxide solution.
The co-precipitation reaction was started by simultaneously feeding an aqueous transition metal sulfate solution and aqueous sodium hydroxide solution, and a total flow rate resulting in an average residence time of 8 hours. The transition metal sulfate solution contained the sulfates of Ni, Co and Mn at a molar ratio of 88:7:5 and a total transition metal concentration of 1.65 mol/kg. The aqueous sodium hydroxide solution was a 25 wt.% sodium hydroxide solution and wt.% ammonia solution in a weight ratio of 6. The pH value was kept at 12 by the separate 20 feed of an aqueous sodium hydroxide solution. Beginning with the start-up of all feeds, the re-sultant slurry was removed continuously.
The slurry was then filtered in a filter press. The resultant filter cake was washed with de-ionized water and then with aqueous sodium hydroxide solution. The resultant wet filter cake of precur-25 sor was obtained, residual water content 9.5% by weight, referring to the overall filter cake, av-erage particle diameter (d50) of 11 pm, span [(d90)-(dio) divided by (d50)]:
1.4.
II. Drying of the filter cake 11.1 Drying and de-watering in a rotary kiln with 5 heating zones The wet filter cake resulting from Example I: was then fed to a continuously operated electrically heated rotary kiln, mass flow rate of 20 kg/h. The rotary kiln had a heated length of 6m and an inner diameter of 0.3 m and was heated of a length of 6 m by an external electrical resistance furnace, with five evenly distributed heating zones. The set temperature was set to 200 and 240 C in the first two zones measured from the solids feed side (drying zone) and 320, 440, 490 C
in the last heating three zones (hydroxide decomposition zones). The average residence time of the particulate material amounted to 90 min in the heated section of the kiln.
The volume flow of
The invention is further illustrated by the following working examples.
General: dio, dal and d90 refer to the particle diameters at 10, 50 and 90 %
of the cumulative volume distribution).
I. Co-precipitation of a precursor A continuous stirred tank reactor was filled with deionized water and 49 g of ammonium sulfate per kg of water. The solution was tempered to 55 C and a pH value of 12 was adjusted by add-ing an aqueous sodium hydroxide solution.
The co-precipitation reaction was started by simultaneously feeding an aqueous transition metal sulfate solution and aqueous sodium hydroxide solution, and a total flow rate resulting in an average residence time of 8 hours. The transition metal sulfate solution contained the sulfates of Ni, Co and Mn at a molar ratio of 88:7:5 and a total transition metal concentration of 1.65 mol/kg. The aqueous sodium hydroxide solution was a 25 wt.% sodium hydroxide solution and wt.% ammonia solution in a weight ratio of 6. The pH value was kept at 12 by the separate 20 feed of an aqueous sodium hydroxide solution. Beginning with the start-up of all feeds, the re-sultant slurry was removed continuously.
The slurry was then filtered in a filter press. The resultant filter cake was washed with de-ionized water and then with aqueous sodium hydroxide solution. The resultant wet filter cake of precur-25 sor was obtained, residual water content 9.5% by weight, referring to the overall filter cake, av-erage particle diameter (d50) of 11 pm, span [(d90)-(dio) divided by (d50)]:
1.4.
II. Drying of the filter cake 11.1 Drying and de-watering in a rotary kiln with 5 heating zones The wet filter cake resulting from Example I: was then fed to a continuously operated electrically heated rotary kiln, mass flow rate of 20 kg/h. The rotary kiln had a heated length of 6m and an inner diameter of 0.3 m and was heated of a length of 6 m by an external electrical resistance furnace, with five evenly distributed heating zones. The set temperature was set to 200 and 240 C in the first two zones measured from the solids feed side (drying zone) and 320, 440, 490 C
in the last heating three zones (hydroxide decomposition zones). The average residence time of the particulate material amounted to 90 min in the heated section of the kiln.
The volume flow of
8 the countercurrent gas flow (air) amounted to 20 m3/h, determined at standard conditions. The air inlet temperature was at ambient temperature.
As a result, a fine powder of a dehydroxylated metal oxide was obtained with a residual mois-ture content of 500 ppm, determined by Karl-Fischer titration, and with a phase pattern charac-teristic for nickel oxide (bunsenite) as determined by powder X-Ray diffraction measurements.
11.2 Drying and de-watering in a rotary kiln The wet filter cake resulting from Example I. was then fed to a continuously operated electrically heated rotary kiln, mass flow rate of 20 kg/h. The rotary kiln had a heated length of 2.3 m and an inner diameter of 0.26 m and was heated of a length of 6 m by an external electrical re-sistance furnace. The set temperature was set to 475 C. The average residence time of the particulate material amounted to 45 min in the heated section of the kiln. The volume flow of the countercurrent gas flow (air) amounted to 3 m3/h, determined at standard conditions. The air inlet temperature was at ambient temperature.
As a result, a fine powder of a dehydroxylated metal oxide was obtained with a residual mois-ture content of 0.45% by weight, determined by Karl-Fischer titration, with a BET specific sur-face area of 60 m2/g (determined by N2 adsorption method), and with a phase pattern character-istic for nickel oxide (bunsenite) as determined by powder X-Ray diffraction measurements.
11.3 Drying in a rotary kiln (comparative) without removal of hydroxyl groups The wet filter cake resulting from Example I. was subsequently fed to a continuously operated electrically heated rotary kiln with a mass flow rate of 1.5 kg/h. The rotary kiln had a heated length of 1 m and an inner diameter of 0.1 m The kiln was operated at a furnace temperature of approx. 150 'C. The average residence time of the particulate material amounted to 50 min in the heated section of the kiln. The volume flow of the countercurrent gas flow (air) amounted to 1 Nm3/h. As a result, a fine powder of a dehydroxylated metal oxide was obtained with a BET
specific surface area of 33 m2/g, residual water content of 1 wt% and total LOI (loss on ignition) of 21.2 wt%. The comparative precursor so obtained showed a crystal phase pattern character-istic for nickel hydroxide (theophrastite).
As a result, a fine powder of a dehydroxylated metal oxide was obtained with a residual mois-ture content of 500 ppm, determined by Karl-Fischer titration, and with a phase pattern charac-teristic for nickel oxide (bunsenite) as determined by powder X-Ray diffraction measurements.
11.2 Drying and de-watering in a rotary kiln The wet filter cake resulting from Example I. was then fed to a continuously operated electrically heated rotary kiln, mass flow rate of 20 kg/h. The rotary kiln had a heated length of 2.3 m and an inner diameter of 0.26 m and was heated of a length of 6 m by an external electrical re-sistance furnace. The set temperature was set to 475 C. The average residence time of the particulate material amounted to 45 min in the heated section of the kiln. The volume flow of the countercurrent gas flow (air) amounted to 3 m3/h, determined at standard conditions. The air inlet temperature was at ambient temperature.
As a result, a fine powder of a dehydroxylated metal oxide was obtained with a residual mois-ture content of 0.45% by weight, determined by Karl-Fischer titration, with a BET specific sur-face area of 60 m2/g (determined by N2 adsorption method), and with a phase pattern character-istic for nickel oxide (bunsenite) as determined by powder X-Ray diffraction measurements.
11.3 Drying in a rotary kiln (comparative) without removal of hydroxyl groups The wet filter cake resulting from Example I. was subsequently fed to a continuously operated electrically heated rotary kiln with a mass flow rate of 1.5 kg/h. The rotary kiln had a heated length of 1 m and an inner diameter of 0.1 m The kiln was operated at a furnace temperature of approx. 150 'C. The average residence time of the particulate material amounted to 50 min in the heated section of the kiln. The volume flow of the countercurrent gas flow (air) amounted to 1 Nm3/h. As a result, a fine powder of a dehydroxylated metal oxide was obtained with a BET
specific surface area of 33 m2/g, residual water content of 1 wt% and total LOI (loss on ignition) of 21.2 wt%. The comparative precursor so obtained showed a crystal phase pattern character-istic for nickel hydroxide (theophrastite).
Claims (9)
1. Process for removing water from a particulate material selected from (oxy)hydroxides and carbonates containing at least one transition metal selected from of nickel or cobalt and at least one metal other than nickel, said process comprising the step of introducing at least one particulate material with a water content in the range of from 1 to 30 %
by weight, re-ferring to said particulate material, into a rotary kiln with extemal heating elements and moving it through the rotary kiln together with a flow of a gas, wherein the average resi-dence time of the particulate material is in the range of from 30 minutes to 5 hours and wherein the residual moisture of the resultant product is in the range of frorn 50 ppm to 1.5% by weight.
by weight, re-ferring to said particulate material, into a rotary kiln with extemal heating elements and moving it through the rotary kiln together with a flow of a gas, wherein the average resi-dence time of the particulate material is in the range of from 30 minutes to 5 hours and wherein the residual moisture of the resultant product is in the range of frorn 50 ppm to 1.5% by weight.
2. Process according to claim 1 wherein the flow of gas is counter-current with respect to the movement of the particulate material.
3. Process according to claim 1 or 2 wherein such particulate material is selected from com-posite (oxy)hydroxides of nickel and at least one transition metal selected from cobalt and manganese and containing, optionally, at least one further metal selected from Mg, Al, Ba, Ti, Zr, Nb, Ta, W, Mo, Sb, and Y.
4. Process according to any of the preceding claims wherein such flow of gas has an inlet temperature in the range of from zero to 1400 C.
5. Process according to any of the preceding claims wherein the particulate material is free from lithium.
6. Process according to any of the preceding claim wherein said rotary kiln has at least two distinguishable zones in which the particulate material is treated at different temperature levels.
7. Process according to claim 5 wherein in a first temperature zone the temperature of said particulate material is in the range of from 80 to 130 C and in a second temperature zone, the temperature is in the range of from 200 to 500 C.
8. Process according to any of the preceding claims wherein on the discharge end of said rotary kiln, an inlet stream of inert gas, air, oxygen-enriched or oxygen-depleted air or flue gases are introduced into the rotary kiln.
AMENDED SHEET
PCT/EP 2021/085 257 - 02.02.2023 Application No. PCT/EP2021/085257
AMENDED SHEET
PCT/EP 2021/085 257 - 02.02.2023 Application No. PCT/EP2021/085257
9. Process according to any of the preceding claims wherein the particulate material is se-lected from composite carbonates of nickel and at least one transition metal selected from cobalt and manganese and containing, optionally, at least one further metal selected from 5 Mg, Al, Ba, Ti, Zr, Nb, Ta, W, Mo, Sb, and Y, and wherein the carbonate is at least partial-ly removed as carbon dioxide.
AMENDED SHEET
AMENDED SHEET
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP20215380 | 2020-12-18 | ||
| EP20215380.5 | 2020-12-18 | ||
| PCT/EP2021/085257 WO2022128804A1 (en) | 2020-12-18 | 2021-12-10 | Process for removing water from a particulate material |
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| CA3202011A1 true CA3202011A1 (en) | 2022-06-23 |
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| US (1) | US12656059B2 (en) |
| EP (1) | EP4263434B1 (en) |
| JP (1) | JP2024501508A (en) |
| KR (1) | KR20230119133A (en) |
| CN (1) | CN116507589A (en) |
| CA (1) | CA3202011A1 (en) |
| ES (1) | ES3021461T3 (en) |
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| EP4263434B1 (en) * | 2020-12-18 | 2025-03-19 | Basf Se | Process for removing water from a particulate material |
| JP7699814B2 (en) * | 2021-12-02 | 2025-06-30 | 株式会社林商会 | Drying method for cake containing rare metals |
| JP2025013235A (en) * | 2023-07-11 | 2025-01-24 | 住友化学株式会社 | Metal composite compound powder, method for producing metal composite compound powder, and method for producing positive electrode active material for lithium secondary battery |
| JP2025011494A (en) * | 2023-07-11 | 2025-01-24 | 株式会社田中化学研究所 | Metal composite hydroxide powder, method for producing positive electrode active material for lithium secondary battery, and method for producing metal composite hydroxide powder |
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| US2867522A (en) * | 1951-04-23 | 1959-01-06 | Glenn C Cooley | Method for producing fertilizers and bases from sludges |
| JPS5477297A (en) * | 1977-12-01 | 1979-06-20 | Toray Ind Inc | Manufacture of cobalt hydroxide and/or nickel hydroxide |
| CN1003369B (en) * | 1987-01-12 | 1989-02-22 | 湖南省冶金规划设计院 | Method and equipment for preparing manganese dioxide by pyrolyzing manganese carbonate |
| JP3735886B2 (en) * | 1995-04-28 | 2006-01-18 | 三菱化学株式会社 | Method for producing synthetic quartz powder and method for producing quartz glass molded body |
| US5694701A (en) * | 1996-09-04 | 1997-12-09 | Minnesota Mining And Manufacturing Company | Coated substrate drying system |
| AUPO705697A0 (en) * | 1997-05-28 | 1997-06-19 | Australian Rural Dehydration Enterprise Pty Ltd | Dehydration plant |
| JP3463999B1 (en) * | 2002-05-16 | 2003-11-05 | 三井金属鉱業株式会社 | Manufacturing method of cerium-based abrasive |
| JP4617717B2 (en) * | 2004-05-12 | 2011-01-26 | 三菱化学株式会社 | Lithium transition metal composite oxide and production method thereof, positive electrode for lithium secondary battery and lithium secondary battery |
| JP2006336919A (en) * | 2005-06-01 | 2006-12-14 | Sumitomo Metal Mining Co Ltd | Heating furnace for roasting |
| US9233863B2 (en) * | 2011-04-13 | 2016-01-12 | Molycorp Minerals, Llc | Rare earth removal of hydrated and hydroxyl species |
| WO2014159118A1 (en) * | 2013-03-14 | 2014-10-02 | Applied Materials, Inc. | Apparatus and methods for synthesis of battery-active materials |
| KR20140144959A (en) * | 2013-06-12 | 2014-12-22 | 삼성전자주식회사 | Apparatus for manufacturing a polishing pad and method of manufacturing the same |
| WO2015169913A1 (en) * | 2014-05-08 | 2015-11-12 | Basf Se | Water-absorbing polymer particles |
| PL3224203T3 (en) * | 2014-11-26 | 2019-04-30 | Basf Se | Process for making a lithiated transition metal oxide |
| WO2016162238A1 (en) * | 2015-04-07 | 2016-10-13 | Basf Se | Method for producing super absorber particles |
| EP3412633A1 (en) * | 2017-06-08 | 2018-12-12 | Basf Se | Process for manufacturing an electrode active material |
| EP3652112B1 (en) | 2017-07-14 | 2021-05-19 | Basf Se | Process for making an electrode active material |
| JP7050071B2 (en) * | 2017-11-28 | 2022-04-07 | アモイタングステンニューエナジーマテリアル（アモイ）カンパニーリミテッド | Three-way precursor material and its manufacturing method |
| KR102832928B1 (en) * | 2018-02-28 | 2025-07-10 | 바스프 에스이 | Method for producing coated electrode active material |
| AU2019245807B2 (en) * | 2018-03-26 | 2024-02-08 | Basf Se | Process for making a mixed metal oxide |
| JP6523508B1 (en) | 2018-03-30 | 2019-06-05 | 住友化学株式会社 | Lithium mixed metal compound, positive electrode active material for lithium secondary battery, positive electrode for lithium secondary battery, lithium secondary battery, and method for producing lithium mixed metal compound |
| KR102566856B1 (en) * | 2018-11-07 | 2023-08-11 | 에스케이이노베이션 주식회사 | Method of regenerating lithium precursor and recycling system of lithium precursor |
| US12510296B2 (en) * | 2020-04-21 | 2025-12-30 | Revive Electronics, LLC | Methods and apparatuses for drying electronic devices |
| MX2022014509A (en) * | 2020-05-26 | 2022-12-13 | Ball Corp | Apparatus and method to heat metallic containers or workpieces. |
| US12327854B2 (en) * | 2020-05-30 | 2025-06-10 | Solomon Alema Asfha | Apparatuses and methods for carbon dioxide capturing and electrical energy producing system |
| EP4263434B1 (en) * | 2020-12-18 | 2025-03-19 | Basf Se | Process for removing water from a particulate material |
| WO2024059770A1 (en) * | 2022-09-15 | 2024-03-21 | Velico Medical, Inc. | Rapid spray drying system |
| US12539355B2 (en) * | 2022-09-15 | 2026-02-03 | Velico Medical, Inc. | Dryer for a spray drying system |
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| US12656059B2 (en) | 2026-06-16 |
| WO2022128804A1 (en) | 2022-06-23 |
| JP2024501508A (en) | 2024-01-12 |
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| EP4263434B1 (en) | 2025-03-19 |
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