Process Engineering to Increase the Layered Phase Concentration in the Immediate Products of Flame Spray Pyrolysis

Abstract

Flame-spray-pyrolysis (FSP) is a robust and scalable process to synthesize particles at the commodity-scale. FSP has been used to produce the precursor powders which were converted to the layered structure (R3̅m phase) by a postannealing step in making nickel-rich cathode materials (NCMs). Theoretically, the high flame temperature (normally >1500 K) in FSP can provide adequate energy for the phase conversion from rock-salt to layered structures and potentially enables one-step synthesis. However, the high flame temperature is a critical issue to cause lithium loss and structural degradation, preventing the formation of the layered phase. In this work, guided by the gaseous nucleation theory, we implemented several FSP processes with different solution recipes. The layered phase concentration in the as-burned products can be increased with the solution enthalpies. By adding a rapid quench step to suppress the lithium loss and phase degradation, the layered phase can be further increased. This work contributes new ideas to innovating process regarding the process efficiency and throughput of manufacturing cathode materials at a large scale.

CuO Quantum Dots Supported by SrTiO3 Perovskite Using the Flame Spray Pyrolysis Method: Enhanced Activity and Excellent Thermal Resistance for Catalytic Combustion of CO and CH4

“…The catalyst synthesis methods have a prominent influence on the physical and chemical properties of Cu-based perovskite catalysts. Especially, the flame spray pyrolysis (FSP) technologies prepare catalytic materials under the atomic level and downsize particles to form quantum dots or even single atoms, which can effectively enhance the dispersion and maximize the utilization of the atom. , Because of the one-step rapid synthesis of nanoparticles in a dramatically short time, the copper-based or perovskite materials synthesized by FSP have been covered in plenty of research studies. However, although the remarkable advantages are provided by FSP and copper supported on SrTiO 3 has been widely employed in the environmental field, there are few papers on the synthesis of CuO–SrTiO 3 nanoparticles by FSP and their application for CO and CH 4 catalytic combustion.…”

Flame Synthesis of Carbon and Metal-Oxide Nanoparticles: Flame Types, Effects of Combustion Parameters on Properties and Measurement Methods

“…The liquid is atomized and conveyed by the central nozzle, surrounded by a coflowing oxidizer. An external flame is required to provide a heat source to evaporate and ignite the liquid precursor [ 44 , 46 ] ( Figure 1 e). Because the liquid precursor is highly exothermic, the resultant flame is self-sustaining [ 54 ] and has a high temperature [ 44 ].…”

“…An external flame is required to provide a heat source to evaporate and ignite the liquid precursor [ 44 , 46 ] ( Figure 1 e). Because the liquid precursor is highly exothermic, the resultant flame is self-sustaining [ 54 ] and has a high temperature [ 44 ]. Induced by the entrainment of the surrounding oxidizer, FSP is also characterized by short residence time and steep temperature gradients [ 45 ], with rapid cooling of several hundred K [ 54 ].…”

Rapid Gas-Phase Synthesis of the Perovskite-Type BaCe0.7Zr0.1Y0.1Yb0.1O3−δ Proton-Conducting Nanocrystalline Electrolyte for Intermediate-Temperature Solid Oxide Fuel Cells

“…Particularly, for energy, environmental, and catalysis applications where the mass preparation of tailored functional nanomaterials is urgent, − SFS has attracted extensive attention in recent years. − However, the SFS of complex multi-component materials like BCZYYb still remains challenging. It requires a comprehensive understanding and proper matching of precursor preparation, transformation route, and flame organization.…”