A method and apparatus for continuous fabrication of homogeneous thin flake or
powder electrolyte material from inorganic salt, metallic or similar materials
or from mixtures of such materials for use in Carbonate Fuel Cell ("CFC") power
plants. Electrolyte precursor powders are fed to a continuous blender type mixer
using precision metering equipment that controls material feed rates. The homogenous
mixture of blended powders is then fed into a high temperature melting tank in
which the mixture is melted, forming the desired molten eutectic composition. The
liquid eutectic melt drips from the melting tank through ceramic or metallic nozzles
and splat-cools on a rotating, water-cooled metal cylinder to produce uniform size,
thin flake material. The thin flake electrolyte material can be used as-is, or
it may be further processed using continuous grinding and powder fabrication equipment.
