PROCESS FOR MAKING CATHODE MATERIALS, AND REACTOR SUITABLE FOR CARRYING OUT SAID PROCESS

Abstract

Process for making an at least partially coated particulate material, said process comprising the following steps: (a) providing a particulate material selected from lithiated nickel-cobalt aluminum oxides and layered lithium transition metal oxides, (a) treating said cathode active material with a metal alkoxide or metal amide or alkyl metal compound in a fluidized bed, (b) treating the material obtained in step (b) with moisture in a fluidized bed, and, optionally, repeating the sequence of steps (b) and (c), wherein the superficial gas velocity in the fluidized beds in steps (b) and (c) decreases with increasing reactor height.

Claims

1-16. (canceled)

17. A process for making an at least partially coated particulate material, said process comprising: (a) providing a particulate cathode active material selected from a lithiated nickel-cobalt aluminum oxide and a layered lithium transition metal oxide, (b) treating said cathode active material with a metal alkoxide, a metal amide or an alkyl metal compound in a fluidized bed, to obtain a material, (c) treating the material obtained in (b) with moisture in a fluidized bed, and, optionally, repeating a sequence of (b) and (c), wherein a superficial gas velocity of a gas, which is a gas velocity of the gas with respect to an inner surface of a reactor in the fluidized beds in (b) and (c), decreases with increasing reactor height.

18. The process of claim 17, wherein the alkyl metal compound, the metal alkoxide or the metal amide, respectively, is selected from M.sup.1(R.sup.1).sub.2, M.sup.2(R.sup.1).sub.3, M.sup.3(R.sup.1).sub.4-yH.sub.y, M.sup.1(OR.sup.2).sub.2, M.sup.2(OR.sup.2).sub.3, M.sup.3(OR.sup.2).sub.4, M.sup.3[NR.sup.2).sub.2].sub.4, and methyl alumoxane, wherein R.sup.1 are different or equal and selected from C.sub.1-C.sub.8-alkyl, straight-chain or branched, R.sup.2 are different or equal and selected from C.sub.1-C.sub.4-alkyl, straight-chain or branched, M.sup.1 is selected from Mg and Zn, M.sup.2 is selected from Al and B, M.sup.3 is selected from Si, Sn, Ti, Zr, and Hf, and y is selected from 0 to 4.

19. The process of claim 17 wherein the layered lithium transition metal oxide is a material of general formula (I)
Li.sub.(1+x)[Ni.sub.aCo.sub.bMn.sub.cM.sup.4.sub.d].sub.(1x)O.sub.2(I) wherein M.sup.4 is selected from Mg, Ca, Ba, Al, Ti, Zr, Zn, Mo, V and Fe,
0x0.2
0.1a0.8,
0b0.5,
0.1c0.6,
0d0.1, and
a+b+c+d=1.

20. The process of claim 17, wherein (b) and (c) are performed in a spouted bed.

21. The process of claim 17, wherein the superficial gas velocity in (b) and, if applicable, in (c) is in a range of a pneumatic conveying at an inlet of the gas.

22. The process of claim 17, wherein particles of the lithiated nickel-cobalt aluminum oxide or the layered lithium transition metal oxide, respectively, are cohesive.

23. The process of claim 17, wherein (b) is performed at a temperature in a range of from 15 to 1000 C.

24. The process of claim 17, wherein the reactor is flushed with an inert gas between (b) and (c).

25. The process of claim 17, wherein (b) and (c) are performed in a conical fluidized bed reactor.

26. The process of claim 17, wherein (b) and (c) are performed in a spouted bed with pulsed gas flow of a pulsation gas.

27. The process of claim 26, wherein the reactor for the fluidized bed has at least three inlets that join under a reaction zone and of which one serves for primary fluidizing gas introduction, one serves as a particle outlet and one serves for the pulsation gas.

28. A tubular reactor, comprising at least one conical part and, optionally, at least one part with constant diameter, wherein said tubular reactor has at least four joining inlets that join under a reaction zone, of which one serves as a reactive gas inlet, one serves as a filter purge gas inlet, one serves for primary fluidizing gas introduction, and one serves as a particle outlet and wherein said tubular reactor is suited for carrying out the process of claim 17.

29. The tubular reactor of claim 28, wherein a wall material is selected from ceramic materials and stainless steel that may be coated with aluminum oxide.

30. The tubular reactor of claim 28, having no additional gas distribution elements.

31. A process for chemically coating a particulate material, said process comprising employing the tubular reactor of claim 28.

Description

BRIEF DESCRIPTION OF FIGS. 1 AND 2:

[0083] 1: inlet primary fluidization gas

[0084] 2: inlet pulsation gas

[0085] 3: outlet coated particles

[0086] 4: fluidized bed

[0087] 5: conical part of the reactor, diameter d.sub.1 at the mixing faucet

[0088] 6: cylindrical part of the reactor, diameter d.sub.2

[0089] 7: optional: means for solid-gas separation, for example filter candle or filter cartridge

[0090] 8: optional: inlet for introduction of non-coated particles

[0091] 9: optional: introduction of solid particles

[0092] Solid particular material may be introduced from the top or through inlet 8 or from the bottom of the reactor