Continuous method for manufacture of uniform size flake or powder

An automated method for continuously producing commercial quantities of electrolyte material for use in molten carbonate fuel cells, comprising the steps of:

• feeding measured amounts of precursor powders into a continuous blender, said precursor powders comprising at least one of lithium carbonate, potassium carbonate and sodium carbonate;
• blending said precursor powders until a homogeneous dry powder mixture is obtained;
• continuously adding said homogeneous dry powder mixture to a high-temperature melting tank;
• heating said powder mixture in said melting tank so that it melts, forming a eutectic electrolyte melt;
• cooling said eutectic electrolyte melt by dripping said melt from said melting tank onto a rotating water-cooled cylinder;
• and
• removing the cooled uniform size flakes of electrolyte material from said rotating cylinder.

An automated method for manufacturing electrolyte material for use in molten carbonate fuel cells that continuously removes intolerable fuel cell contaminants, comprising the steps of:

• feeding measured amounts of precursor powders into a continuous blender, said precursor powders comprising at least one of lithium carbonate, potassium carbonate and sodium carbonate;
• blending said precursor powders until a homogeneous dry powder mixture is obtained;
• continuously adding said homogeneous dry powder mixture to a high-temperature melting tank;
• heating said powder mixture in said melting tank so that it melts, forming a eutectic electrolyte melt;
• incorporating getter materials in a liquid melt zone in said melting tank;
• cooling said eutectic electrolyte melt by dripping said melt from said melting tank onto a rotating water-cooled cylinder;
• and
• removing the cooled uniform size flakes of electrolyte material from said rotating cylinder.