'CatContiCryst' - Continuous Manufacture of Li-ion battery Cathode Materials using Oscillating Baffled Reactor/ Crystalliser Technology

Decarbonisation of the world economy is driving an increasing demand for Li-ion batteries, particularly for electric vehicles. The performance of this type of battery technology is heavily dependent on the cathode, of which the layered NMC-type is increasingly popular for delivering high energy densities. Manufacture of NMC precursor materials is typically carried out using conventional batch processes, which bring deficiencies in both production efficiency and quality, impacting battery cost and performance.

NiTech Continuous Oscillating Baffled Reactors/Crystallisers (COBR/C) offer an innovative route for the production such materials. COBR/C technology has proven application in the speciality chemical and pharmaceutical manufacturing sectors, where significant benefits from a continuous processing approach have been demonstrated: substantial reduction in the scale of production units, improved quantity and process control, and access to new processing regimes. In turn this allows manipulation of the chemical reaction and solid-state formation processes that can lead to improved final product performance.

The aim of this project is to demonstrate the technical feasibility of manufacturing NMC precursor materials using COBR/C technology, provide required process data for future scale-up to commercial scale, define the process parameters that allow advantageous manipulation of the NMC properties (specifically in the generation of longer-lifetime single-crystal cathode morphologies), and allow a definition of the benefits of continuous processing over current technologies.

Successful execution of the project would lead to an innovative, efficient, and flexible manufacturing approach being available for industrial scale production, plus the potential of improved performance of the materials produced, a reduction in energy demand for manufacture and a lower capital cost to implement.

The project brings together existing proven technologies -- NMC single crystal precursor synthesis processes and continuous manufacturing, in a synergistic project that could make a significant impact on the target sector.

The project involves NiTech Solutions Ltd as COBR/C process technology provider. Know-how on the chemical & and solid-state processes and cell production and testing is led by the University of Sheffield. CPI will provide facilities and resources for the COBR/C experimental program. Input on raw materials specification, cell KPIs, customer requirements and consumer needs will be provided by Britishvolt. A successful outcome for the project has the potential to make a significant impact on the UK battery supply chain and strengthen the nations position in battery materials production and battery materials technology.