Scaling and Commercializing Continuous Supercritical Hydrothermal Single Crystal Cathode Active Material Manufacturing

Abstract

Current polycrystalline cathode active materials (CAMs) in the market face a significant challenge during charge-discharge cycles. The lithiation and de-lithiation processes induce volume changes within the CAMs, leading to strain along grain boundaries. This strain, arising from the expansion of crystals in different orientations, often results in material pulverization, creating void fractions. Such deterioration leads to increased impedance, capacity degradation, and shorter cycle life.Addressing these challenges, there is an emerging demand for single crystal (SC) CAMs, which promise enhanced performance by eliminating internal void fractions and grain boundaries. The continuous supercritical hydrothermal process, invented at Argonne National Laboratory, offers an innovative and cost-effective method to produce SC CAMs. This method effectively reduces energy consumption and production costs, while also lowering carbon emissions.In this presentation, we provide a comprehensive overview of the advancements in scaling up and commercializing continuous supercritical hydrothermal process for SC CAM manufacturing. Our focus is on the efforts undertaken by ACT-ion Battery Technologies, the industry commercialization partner, highlighting the significant strides made towards implementing this promising solution on a practical level.