A continuous process for producing a material of a battery cell using a system having a mist generator, a drying chamber, one or more gas-solid separators and a reactor is provided. A mist generated from a liquid mixture of two or more metal precursor compounds in desired ratio is dried inside the drying chamber. Heated air or gas is served as the gas source for forming various gas-solid mixtures and as the energy source for reactions inside the drying chamber and the reactor. One or more gas-solid separators are used in the system to separate gas-solid mixtures from the drying chamber into solid particles mixed with the metal precursor compounds and continuously deliver the solid particles into the reactor for further reaction to obtain final solid material particles with desired crystal structure, particle size, and morphology.

Improved methods for preparing lithium transition metal oxide particulate such as lithium nickel metal cobalt oxide (“NMC”) for use in lithium batteries and other applications are disclosed. The lithium transition metal oxide particulate is prepared from appropriate transition metal oxide and Li compound precursors mainly using dry, solid state processes including dry impact milling and heating. Further, novel precursor particulates and novel methods for preparing precursor particles for this and other applications are disclosed.

A process for producing a metal oxide powder by flame spray pyrolysis where a) 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 and d) the solid product is subsequently removed from the reaction stream, wherein e) 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 and f) the slot is arranged such that this gas or vapour brings about a rotation of the flame.

A method for manufacturing bacterially induced crystal particle includes culturing bacteria in a culture medium including a carbon source and a raw metal material including a transition metal, so that the bacteria induce a raw metal material to undergo a reduction-oxidation reaction; isolating a wet powder material from the culture medium; and drying the wet powder material to obtain a powder material. The powder material includes at least one bacterially induced crystal particle.

A method for manufacturing bacterially induced crystal particle includes culturing bacteria in a culture medium including a carbon source and a raw metal material including a transition metal, so that the bacteria induce a raw metal material to undergo a reduction-oxidation reaction; isolating a wet powder material from the culture medium; and drying the wet powder material to obtain a powder material. The powder material includes at least one bacterially induced crystal particle.

Simple, material-efficient microgranulation methods are disclosed for aggregating precursor particles into larger product particles with improved properties and, in some instances, novel structures. The product particles are useful in applications requiring uniform, smooth, spherical, or rounded particles such as for electrode materials in lithium batteries and other applications.

Simple, material-efficient microgranulation methods are disclosed for aggregating precursor particles into larger product particles with improved properties and, in some instances, novel structures. The product particles are useful in applications requiring uniform, smooth, spherical, or rounded particles such as for electrode materials in lithium batteries and other applications.

A method for preparing porous inorganic particles is disclosed. The method includes the steps of: (a) preparing an emulsion comprising an inorganic precursor and a polar solvent; (b) adding an organic solvent to the emulsion of step (a) to swell emulsion particles; (c) mixing the swollen emulsion of step (b) with polymer particles having a positive charge on the surface thereof; (d) adding a surfactant to the mixture of step (c) and removing the organic solvent; (e) adding an initiator to the result of step (d) to polymerize the same; and (f) firing the result of step (e) to remove the polymer particles so as to form macropores.

A method for preparing porous inorganic particles is disclosed. The method includes the steps of: (a) preparing an emulsion comprising an inorganic precursor and a polar solvent; (b) adding an organic solvent to the emulsion of step (a) to swell emulsion particles; (c) mixing the swollen emulsion of step (b) with polymer particles having a positive charge on the surface thereof; (d) adding a surfactant to the mixture of step (c) and removing the organic solvent; (e) adding an initiator to the result of step (d) to polymerize the same; and (f) firing the result of step (e) to remove the polymer particles so as to form macropores.

There are provided processes for preparing a metal hydroxide comprising (i) at least one metal chosen from nickel and cobalt and optionally (ii) at least one metal chosen from manganese, lithium, copper, magnesium and aluminum, the process comprising: reacting a metal sulfate comprising (i) at least one metal chosen from nickel and cobalt and optionally (ii) at least one metal chosen from manganese, lithium, copper, magnesium and aluminum with lithium hydroxide, sodium hydroxide and/or potassium hydroxide and optionally a chelating agent in order to obtain a solid comprising the metal hydroxide and a liquid comprising lithium sulfate, sodium sulfate and/or potassium sulfate; separating the liquid and the solid from one another to obtain the metal hydroxide; submitting the liquid comprising lithium sulfate, sodium sulfate and/or potassium sulfate to an electromembrane process for converting the lithium sulfate, sodium sulfate and/or potassium sulfate into lithium hydroxide, sodium hydroxide and/or potassium hydroxide respectively; reusing the sodium hydroxide obtained by the electromembrane process for reacting with the metal sulfate; and reusing the lithium hydroxide obtained by the electromembrane process for reacting with the metal sulfate and/or with the metal hydroxide.