公开(公告)号：US11701630B2

公开(公告)日：2023-07-18

申请号：US17886756

申请日：2022-08-12

Applicant: CALIX LTD

Inventor： Mark Sceats ,  Philip Hodgson ,  Adam Vincent ,  Simon Thomsen ,  Matthew Gill ,  Daniel Rennie

IPC: B01J6/00 ,  B82Y30/00 ,  B82Y40/00 ,  C01B13/18 ,  C04B2/10 ,  C04B7/44

CPC classification number: B01J6/004 ,  B82Y30/00 ,  B82Y40/00 ,  C01B13/18 ,  C01B13/185 ,  C04B2/10 ,  C04B2/102 ,  C04B7/44 ,  B01J2219/00051 ,  C01P2004/61 ,  C01P2006/12

Abstract: A method and system for producing nano-active powder materials. The method can be used with a reactor system comprising stages in which input particles flow under gravity progressively through stages of the reactor. A powder injector first stage in which ground input precursor powder is injected into the reactor. An externally heated preheater stage may be in the reactor, in which the precursor powder is heated to a temperature of calcination reaction. An externally heated calciner stage in the reactor, in which primary precursor volatile constituents can be rapidly removed calcination reactions as a high purity gas stream to produce the desired nano-active product. A post-processing reactor stage in which there is a change of the gas stream composition to produce the desired hot powder product by virtue of the nano-activity of the first powder material. A powder ejector stage in which the hot powder product is ejected from the reactor.

公开(公告)号：US20220162097A1

公开(公告)日：2022-05-26

申请号：US17646428

申请日：2021-12-29

Applicant: Calix Ltd

Inventor： Mark Sceats ,  Adam Vincent

IPC: C02F1/68 ,  C01F5/16 ,  C01B13/14 ,  C04B2/04 ,  B01J19/18 ,  B01J13/00 ,  C02F1/52 ,  C02F1/66

Abstract: A method of manufacture of high-solids hydroxide slurries from caustic calcined carbonate powder is described, whereby the properties of the slurry are its low resistance to shear thinning to facilitate transport, a high stability for transport and storage, ease of reconstitution after long periods of storage, and, as required, a high concentration of chemically reactive species at the particle surface. The method achieves these specifications by mixing caustic calcined carbonate or hydroxide powder with water in an insulated reactor vessel, and agitating the slurry sufficiently such that the hydration reaction causes the water to spontaneously boil, such that the remaining hydration proceeds spontaneously under the fixed conditions of boiling through the water loss. The mixing process is preferably carried out by a shear pump. A viscosity modifier, such as acetic acid, is used to thin the slurry to enable the mixing system to maintain uniform mixing. The reaction is terminated when the boiling has spontaneously ceased and the temperature has spontaneously dropped to a set point though the reactor heat losses, where the processing time is sufficiently long that the slurry meets the desired specifications.

公开(公告)号：US20170035053A1

公开(公告)日：2017-02-09

申请号：US15106759

申请日：2014-12-10

Applicant: Calix Ltd.

Inventor： Mark Sceats

IPC: A01N59/06 ,  B01J21/10 ,  A01N25/12 ,  B01J35/10 ,  C04B2/10 ,  C01F5/06 ,  B01J35/02

CPC classification number: A01N59/06 ,  A01N25/12 ,  B01J21/10 ,  B01J35/026 ,  B01J35/1019 ,  B82Y40/00 ,  C01F5/06 ,  C01P2004/61 ,  C01P2006/12 ,  C04B2/102 ,  C04B2/106 ,  A01N25/04

Abstract: A process and apparatus for manufacture of oxide products for use as biocide, chemical detoxifying, and catalytic support products, from caustic calcined carbonate powder, preferably from magnesite, dolomite, or hydromagnesite, is described. These oxide particles are characterized by high surface area, high porosity and a high degree of calcination, and the method of manufacture of utilizes an indirectly heated counterflow reactor. The oxides may be used as a powder, granules, or formulated into a slurry and used as a spray, emulsion, foam or fog, or the powder product may be directly applied. Also described is the formation of particles with microstructures defined by at least one nano-crystalline structure positioned on the outer surface of the particles.

Abstract translation: 描述了用于制备用于杀生物剂，化学解毒和催化支持产物的氧化物产品的方法和设备，其由苛性煅烧碳酸盐粉末，优选菱镁矿，白云石或氢化镁石制成。 这些氧化物颗粒的特征在于高表面积，高孔隙率和高煅烧程度，并且制造方法利用间接加热的逆流反应器。 氧化物可以用作粉末，颗粒或配制成浆料并用作喷雾，乳液，泡沫或雾，或者可以直接施用粉末产品。 还描述了由位于颗粒的外表面上的至少一个纳米晶体结构限定的微结构的颗粒的形成。

公开(公告)号：US20230357086A1

公开(公告)日：2023-11-09

申请号：US17610399

申请日：2020-05-13

Applicant: CALIX LTD

Inventor： Mark Sceats

IPC: C04B35/645 ,  C04B35/626 ,  C04B35/111 ,  C04B35/053 ,  C04B35/575

CPC classification number: C04B35/053 ,  C04B35/111 ,  C04B35/575 ,  C04B35/62645 ,  C04B35/645 ,  C04B2235/3206 ,  C04B2235/3217 ,  C04B2235/3826 ,  C04B2235/5463 ,  C04B2235/61 ,  C04B2235/77 ,  C04B2235/781

Abstract: The invention provides a process for manufacturing ceramics and refractories comprising the steps of producing a porous powder comprising nanograin sized particles wherein the particles have a Young’s modulus value that is smaller in value compared to the same crystalline material; compacting and processing the powder such that the powder forms a stable homogeneous composite; and sintering the composite for a time and temperature to lead to uniform shrinkage of the composite to make a dense homogenous material.

公开(公告)号：US20220387951A1

公开(公告)日：2022-12-08

申请号：US17886756

申请日：2022-08-12

Applicant: CALIX LTD

Inventor： Mark Sceats ,  Philip Hodgson ,  Adam Vincent ,  Simon Thomsen ,  Matthew Gill ,  Daniel Rennie

IPC: B01J6/00 ,  B82Y30/00 ,  B82Y40/00 ,  C01B13/18 ,  C04B2/10 ,  C04B7/44

Abstract: A method and system for producing nano-active powder materials. The method can be used with a reactor system comprising stages in which input particles flow under gravity progressively through stages of the reactor. A powder injector first stage in which ground input precursor powder is injected into the reactor. An externally heated preheater stage may be in the reactor, in which the precursor powder is heated to a temperature of calcination reaction. An externally heated calciner stage in the reactor, in which primary precursor volatile constituents can be rapidly removed calcination reactions as a high purity gas stream to produce the desired nano-active product. A post-processing reactor stage in which there is a change of the gas stream composition to produce the desired hot powder product by virtue of the nano-activity of the first powder material. A powder ejector stage in which the hot powder product is ejected from the reactor.

公开(公告)号：US20210143389A1

公开(公告)日：2021-05-13

申请号：US16476662

申请日：2018-01-12

Applicant: CALIX LTD

Inventor： Mark Sceats ,  Phllip Hodgson ,  Khokan Kanti Majumder

IPC: H01M4/04 ,  H01M4/505 ,  H01M4/525 ,  H01M4/133 ,  H01M4/1393

Abstract: A process for producing a cathode or anode material adapted for use in the manufacture of fast rechargeable ion batteries. The process may include the steps of Selecting an precursor material that, upon heating in a gas stream, releases volatile compounds to create porous materials to generate a material compound suitable for an electrode in an ion battery. Grinding the precursor material to produce a powder of particles with a first predetermined particle size distribution to form a precursor powder. Calcining the precursor powder in a flash calciner reactor segment with a first process gas at a first temperature to produce a porous particle material suitable for an electrode in an ion battery, and having the pore properties, surface area and nanoscale structures for applications in such batteries. Processing the hot precursor powder in a second calciner reactor segment with a second process gas to complete the calcination reaction, to anneal the material to optimise the particle strength, and to modify the oxidation state of the product for maximising the charge density when the particle is activated in a battery cell to form a second precursor powder. Quenching the second precursor powder. Activating the particles of the second precursor powder in an electrolytic cell by the initial charging steps to intercalate electrolyte ions in the particles.

公开(公告)号：US20170320774A1

公开(公告)日：2017-11-09

申请号：US15527478

申请日：2015-11-11

Applicant: Calix Ltd

Inventor： Mark Sceats

IPC: C04B2/10 ,  B01J27/232 ,  B01J6/00

Abstract: A process for producing a highly calcined and uniformly calcined product from a feedstock. The process comprising the steps of grinding the feedstock to powder, preheating the powder, and calcining the powder in a reactor plant that comprises a number of reactor segments in which a flash calciner is used in each progressive reactor segment to incrementally react the powder by raising the temperature in each segment. The last segment may be a high-temperature reactor that has a controlled residence time and temperature that may allow controlled finishing of the calcination process to achieve a desired degree of calcination and sintering of the product; and cooling of the product.

公开(公告)号：US11695103B2

公开(公告)日：2023-07-04

申请号：US16476662

申请日：2018-01-12

Applicant: CALIX LTD

Inventor： Mark Sceats ,  Philip Hodgson ,  Khokan Kanti Majumder

IPC: H01M4/04 ,  H01M4/133 ,  H01M4/1393 ,  H01M4/505 ,  H01M4/525

CPC classification number: H01M4/0416 ,  H01M4/0447 ,  H01M4/0459 ,  H01M4/133 ,  H01M4/1393 ,  H01M4/505 ,  H01M4/525

Abstract: A process for producing a cathode or anode material adapted for use in the manufacture of fast rechargeable ion batteries. The process may include the steps of Selecting an precursor material that, upon heating in a gas stream, releases volatile compounds to create porous materials to generate a material compound suitable for an electrode in an ion battery. Grinding the precursor material to produce a powder of particles with a first predetermined particle size distribution to form a precursor powder. Calcining the precursor powder in a flash calciner reactor segment with a first process gas at a first temperature to produce a porous particle material suitable for an electrode in an ion battery, and having the pore properties, surface area and nanoscale structures for applications in such batteries. Processing the hot precursor powder in a second calciner reactor segment with a second process gas to complete the calcination reaction, to anneal the material to optimise the particle strength, and to modify the oxidation state of the product for maximising the charge density when the particle is activated in a battery cell to form a second precursor powder. Quenching the second precursor powder. Activating the particles of the second precursor powder in an electrolytic cell by the initial charging steps to intercalate electrolyte ions in the particles.

公开(公告)号：US10570061B2

公开(公告)日：2020-02-25

申请号：US15039693

申请日：2014-11-19

Applicant: Calix Ltd.

Inventor： Mark Sceats

IPC: C04B2/10 ,  C04B7/43 ,  C04B7/00 ,  C04B7/34 ,  C04B28/00 ,  C04B32/00 ,  C04B9/12 ,  C04B28/04 ,  C04B111/00

Abstract: A method of manufacture of Portland cement clinker is described in a dry process that captures the carbon dioxide emitted from the calcination of carbonate minerals, principally limestone. The process uses an indirectly heated, counter-flow reactor to pre-heat and calcine the cement meal to produce a separate calcined meal and carbon dioxide gas stream, with external heat being provided by the combustion of a secondary fuel stream with pre-heated air. This calcined meal is injected into the conventional rotary kiln, where the hot flue gas from combustion of the primary fuel with pre-heated air is used to fuse, react and sinter the powders to form granules of cement clinker. The clinker and carbon dioxide streams are cooled by the air pre-heaters.

公开(公告)号：US20170050883A1

公开(公告)日：2017-02-23

申请号：US15039693

申请日：2014-11-19

Applicant: Calix Ltd.

Inventor： Mark Sceats

IPC: C04B7/43

Abstract: A method of manufacture of Portland cement clinker is described in a dry process that captures the carbon dioxide emitted from the calcination of carbonate minerals, principally limestone. The process uses an indirectly heated, counter-flow reactor to pre-heat and calcine the cement meal to produce a separate calcined meal and carbon dioxide gas stream, with external heat being provided by the combustion of a secondary fuel stream with pre-heated air. This calcined meal is injected into the conventional rotary kiln, where the hot flue gas from combustion of the primary fuel with pre-heated air is used to fuse, react and sinter the powders to form granules of cement clinker. The clinker and carbon dioxide streams are cooled by the air pre-heaters.

Abstract translation: 在干法中描述了波特兰水泥熟料的制造方法，其捕获从碳酸盐矿物（主要是石灰石）的煅烧中排出的二氧化碳。 该方法使用间接加热的逆流反应器来预热和煅烧水泥粉，以产生单独的煅烧膳食和二氧化碳气体流，其中通过二次燃料流与预热空气的燃烧提供外部热量 。 将这种煅烧的粉末注入常规的回转窑中，其中来自主燃料与预热空气的燃烧的热烟道被用于熔融，反应和烧结粉末以形成水泥熟料的颗粒。 熟料和二氧化碳流由空气预热器冷却。