The production and processing of cathode active materials (CAM) are among the largest contributors to the cost of lithium-ion battery manufacturing. Typical CAM manufacture involves multiple, multi-phase steps in a co-precipitation process that requires a large amount of water and creates a significant amount of solid sodium-sulfate waste. A new, all-solid-state CAM technology aims to lower costs and create less waste in CAM production. The single-step CAM-synthesis process developed by Sylvatex Inc. (Alameda, Calif.; www.sylvatex.com) requires no water, and is similar to a typical milling process. “Our goal is to use mixed hydroxide precipitate [MHP], containing both nickel and cobalt hydroxides, as raw material. Typically, the metal hydroxides in MHP must be converted to metal sulfates before CAM synthesis, but we can use the hydroxides themselves, so we’re cutting out a key portion of the process costs,” explains Joe Adiletta, vice president of battery commercialization at Sylvatex.
This process also simplifies CAM synthesis in that the lithium hydroxide can be added alongside the other metals. Also key to the Sylvatex technology is a proprietary solid additive that acts as a reaction facilitator amongst the metals. “Normally, the lithium must be added later in the process, necessitating multiple steps. The output of our milling process goes directly to calcination. Since the process is analogous to traditional milling, it can use commercial, off-the-shelf equipment, allowing this pathway to scale relatively quickly,” comments Adiletta. Going into the calcination step, the process can take advantage of heat created by the exothermic reaction facilitated by the additive, essentially lowering the heating requirements.
Sylvatex has reported 25% lower costs for its CAM compared to conventional production methods, along with a 50% reduction in carbon footprint.
Source: Sylvatex