NCM Cathode Research Articles

Improving Fast-Charging Performance of Lithium-Ion Batteries through Electrode-Electrolyte Interfacial Engineering.

The solid-electrolyte interphase (SEI) is a key element in anode-electrolyte interactions and ultimately contributes to improving the lifespan and fast-charging capability of lithium-ion batteries. The conventional additive vinyl carbonate (VC) generates spatially dense and rigid poly VC species that may not ensure fast Li+ transport across the SEI on the anode. Here, a synthetic additive called isosorbide 2,5-dimethanesulfonate (ISDMS) with a polar oxygen-rich motif is reported that can competitively coordinate with Li+ ions and allow the entrance of PF6 - anions into the core solvation structure. The existence of ISDMS and PF6 - in the core solvation structure along with Li+ ions enables the movement of anions toward the anode during the first charge, leading to a significant contribution of ISDMS and LiPF6 to SEI formation. ISDMS leads to the creation of ionically conductive and electrochemically stable SEI that can elevate the fast-charging performance and increase the lifespan of LiNi0.8Co0.1Mn0.1O2 (NCM811)/graphite full cells. Additionally, a sulfur-rich cathode-electrolyte interface with a high stability under elevated-temperature and high-voltage conditions is constructed through the sacrificial oxidation of ISDMS, thus concomitantly improving the stability of the electrolyte and the NCM811 cathode in a full cell with a charge voltage cut-off of 4.4V.

Electrolyte Engineering to Construct Robust Interphase with High Ionic Conductivity for Wide Temperature Range Lithium Metal Batteries.

Unstable interphase formed in conventional carbonate-based electrolytes significantly hinders the widespread application of lithium metal batteries (LMBs) with high-capacity nickel-rich layered oxides (e.g., LiNi0.8Co0.1Mn0.1O2, NCM811) over a wide temperature range. To balance ion transport kinetics and interfacial stability over wide temperature range, herein a bifunctional electrolyte (EAFP) tailoring the electrode/electrolyte interphase with 1,3-propanesultone as an additive was developed. The resulting cathode-electrolyte interphase with an inorganic inner layer and an organic outer layer possesses high mechanical stability and flexibility, alleviating stress accumulation and maintaining the structural integrity of the NCM811 cathode. Meanwhile, the inorganic-rich solid electrolyte interphase inhibits electrolyte side reactions and facilitates fast Li+ transport. As a result, the Li||Li cells exhibit stable performance in extensive temperatures with low overpotentials, especially achieving a long lifespan of 1000 h at 30 °C. Furthermore, the optimized EAFP is also suitable for LiFePO4 and LiCO2 cathodes (1000 cycles, retention: 67 %). The Li||NCM811 and graphite||NCM811 pouch cells with lean electrolyte (g/Ah grade) operate stably, verifying the broad electrode compatibility of EAFP. Notably, the Li||NCM811 cells can operate in wide climate range from -40 °C to 60 °C. This work establishes new guidelines for the regulation of interphase by electrolytes in all-weather LMBs.

Poly (Propylene Carbonate) with Extremely Alternating Structure Used as Binders for High-Loading Cathodes by Solvent-Free Method in High-Performance NCM811 Batteries.

The cathode affects the capacity, working voltage, and cost of lithium-ion batteries. Although the binder is a small part of the cathode material, it is particularly important to the performance of the batteries. Therefore, the design and development of polymer binders with different structures and characteristics is an important topic. In this paper, an NCM811 cathode (PPC-NCM) was prepared by a solvent-free method using poly (propylene carbonate) (PPC) as the binder, with an active substance loading of 10 mg/cm2. To explore the effect of the PPC binder on the electrochemical performance of the NCM811 cathode, the discharge capacity was 112.2 mAh/g with a 76.1% capacity retention after cycling more than 200 cycles at 1 C, which has a significantly better cycling performance than that of a PVDF-NCM/Li battery. The PPC/NCM/graphite full cells were also assembled to demonstrate the practical application potential of this work. It was shown that PPC as a binder can improve the cycling stability of NCM811/Li and NCM811/graphite full cells. The PPC binder used in the NCM811 cathode not only makes it extremely easy to prepare dry electrodes, but also makes it very simple to recover the electrode material by heating in the case of battery failure. This paper provides a new idea for the industrialization and development of a novel binder.

Graphite Regeneration and NCM Cathode Type Synthesis from Retired LIBs by Closed-Loop Cycle Recycling Technology of Lithium-Ion Batteries

A closed-loop regeneration process for spent LiCoO2 has been successfully designed with prior synthesis of LiNixCoyMnzO2, by the authors. This research applies the methodology to lithium-ion battery anodes, using spent graphite from a decommissioned battery in a leaching process with 1.5 mol∙L−1 malic acid and 3% H2O2 alongside LiCoO2. The filtered graphite was separated, annealed in an argon atmosphere, and the filtrate was used to synthesize NCM cathode material. Characterization involved X-ray diffraction, EDX, and SEM techniques. The regenerated graphite (RG) showed a specific discharge capacity of 340.4 mAh/g at a 0.1C rate in the first cycle, dropping to 338.4 mAh/g after 55 cycles, with a Coulombic efficiency of 99.9%. CV and EIS methods provided further material assessment. In a related study, the SNCM111 synthesized from the leaching solution showed a specific discharge capacity of 131.68 mAh/g initially, decreasing to 115.71 mAh/g after 22 cycles.

Engineering Molecule‐Designed In Situ Polymerization on Al‐Doped Molecular‐Sieve Framework Enables Robust Quasi‐Solid‐State Lithium Batteries

AbstractAchieving fast Li+ transport kinetics and stable electrode/electrolyte interfaces is of paramount importance, yet extremely challenging for the practical success of solid‐state lithium metal batteries, which requires the rational design of the structure and composition of solid‐state electrolytes. Herein, a composite quasi‐solid‐state electrolyte is fabricated through in situ polymerization of a molecule‐designed polymer chain within the functionalized molecular sieve framework (Al‐MCM41). In this design, the robust Brønsted/Lewis acid–base interactions between Al‐MCM41 and TFSI− facilitate the dissociation of lithium salt, leading to a Li+ transference number as high as 0.81. Meanwhile, the well‐ordered mesopores of Al‐MCM41 act as the “reservoir” of the polymer chain, creating continuous ionic migration pathways to offer an excellent Li+ conductivity of 1.09 × 10−3 S cm−1 at 30 °C. Furthermore, the polymer with fluorinated and nitrided functional groups guarantees a dual‐reinforced anode and cathode interface. Such an integrated electrolyte with simultaneous unimpeded Li+ transport and robust interfaces delivers extraordinary capacity retention of 84.6% over 600 cycles at 5 C when coupled with LiFePO4 cathode and remarkable reversible capacity of 129.0 mAh g−1 after 200 cycles with high‐voltage NCM622 cathode. This work provides a significant avenue for enhancing the practical feasibility of solid‐state lithium metal batteries.

Cover Feature: Cost‐Effective Solutions for Lithium‐Ion Battery Manufacturing: Comparative Analysis of Olefine and Rubber‐Based Alternative Binders for High‐Energy Ni‐Rich NCM Cathodes (ChemElectroChem 21/2024)

Cover Feature: Cost‐Effective Solutions for Lithium‐Ion Battery Manufacturing: Comparative Analysis of Olefine and Rubber‐Based Alternative Binders for High‐Energy Ni‐Rich NCM Cathodes (ChemElectroChem 21/2024)

Constructing an Artificial Interface as a Bifunctional Promoter for the Li Anode and the NCM Cathode in Lithium Metal Batteries.

The bottleneck of Li metal batteries toward practical applications lies at inferior cyclability as well as Li dendrite issues. As a promising solution, an interface engineering strategy is proposed herein for the Li anode through constructing a hybrid artificial interface. It is assembled onto the Li anode using photocontrolled free radical polymerization (photo-CRP) of polyethylene glycol diacrylate-hexafluorobutyl methacrylate and hexafluorobutyl methacrylate-trifluoroethyl carbonate (PEGDA-HFMBA@HFMBA-FEMC or PH@HF layer). Among such hybrid interfaces, the interior layer of PEGDA-HFMBA exists as a protective shield with flexibility and fracture resistance, while the exterior layer of HFMBA-FEMC plays a role as a LiF reservoir to promote Li mass transfer and its even electrodeposition. In the meantime, some excess HFMBA and FEMC monomers further dissolve into the electrolyte as molecular additives, followed by in situ generation of a thin and robust LiF-rich cathode electrolyte interface (CEI). With the resulting Li anode, Li/NCM811 full cells showcase multifold cyclability amplification in comparison to cells using Bare-Li, covering durable cyclability with a capacity retention of 81.8% after 400 cycles. When the cutoff voltage is elevated to 4.5 V or the working temperature is elevated to 45 °C, the cells still maintain a stable operation for extending 300 cycles.

Mechanisms of Thermal Decomposition in Spent NCM Lithium-Ion Battery Cathode Materials with Carbon Defects and Oxygen Vacancies.

Resource recovery from retired electric vehicle lithium-ion batteries (LIBs) is a key to sustainable supply of technology-critical metals. However, the mainstream pyrometallurgical recycling approach requires high temperature and high energy consumption. Our study proposes a novel mechanochemical processing combined with hydrogen (H2) reduction strategy to accelerate the breakdown of ternary nickel cobalt manganese oxide (NCM) cathode materials at a significantly lower temperature (450 °C). Particle refinement, material amorphization, and internal energy storage are considered critical success factors for the accelerated decomposition of NCM cathode materials. In our proposed approach, NCM cathode materials can develop active sites with carbon defects (Cv) and oxygen vacancies (Ov), which improve the reduction and breakdown of H2. The adsorbed H2 on the surface of NCM decomposes into H* and combines with oxygen to form OH species, which can be facilitated by Ov via the enhanced charge transfer. The introduced Cv can enhance H2 cracking and generate *C-H species to promote the thermal decomposition of NCM. The presence of defects proves to foster the preferential reduction of Mn(IV) by H2, leading to a lower activation energy for the NCM decomposition (from 139 to 110 kJ/mol) with less H2 consumption. Life cycle assessment suggests a reduction of 4.42 kg CO2 eq for the recycling of every 1.0 kg of retired batteries. This study can promote material circularity and minimize the environmental burden of mining technology-critical metals for a low-carbon transition.

Dissolution of metals in NCM622 cathode through the Dissimilatory process with Na-lactate by Shewanella putrefaciens

Objectives:The objective of this study is to confirm the possibility of reduction and consequent dissolution of Li, Ni, Co, and Mn from NCM622 cathodes in spent Li-ion batteries through the anaerobic respiration with Na-lactate by Shewanella putrefaciens.Methods:The method involves using anaerobic microbial respiration to mimic dissimilatory metal oxide reduction, allowing metals to be leached from NCM622 cathodes (LiNi0.6Co0.2Mn0.2O2) under near-neutral pH conditions (~7.5).Results and Discussion:The results show that approximately 26 wt% of the total Li, Ni, Co, and Mn were successfully leached into the solution within two weeks. This approach differs significantly from conventional acidic leaching processes, offering a more environmentally friendly and sustainable alternative. In addition, we provide quantitative information regarding the dissolution of NCM622 when it is exposed in environmental systems.Conclusion:In conclusion, microbial-based metal leaching presents a novel, sustainable pathway for recovering metals from spent Li-ion batteries, addressing environmental concerns and reducing dependence on traditional energy-intensive recovery methods.

Molecular Engineering Chemical Pre-lithiation Reagent with Low Redox Potential for Graphite Anode Enables High Coulombic Efficiency.

Graphite (Gr) is a low-cost and high-stability anode for lithium-ion batteries (LIBs). However, Gr anode exhibits an obstinate drawback of low initial Coulombic efficiency (ICE), owing to the active lithium loss for the solid electrolyte interphase (SEI) layer. Herein, a straightforward and effective chemical pre-lithiation strategy is proposed to compensate for the lithium loss. A molecular engineering phenanthrene-based lithium-arene complex (Ph-based LAC) reagent is designed by density functional theory (DFT) calculations. The engineering Ph-based reagent enhances the stability of the π-electron system and the electron-donating capacity, resulting in a reduced redox potential to facilitate lithium transfer. The electrochemical distinct of the Ph-based reagent is illustrated, the prelithiation process in a low Li-insertion platform, and the lithiation degree is controllable with the dipping time (ICE = 102%, 3min). Notably, a denser and homogeneous SEI layer has pre-formed to enhance the Li+ transport and interface stability. Moreover, the lithium-ion full batteries assemble with LiFePO4 and NCM811 cathode, which exhibits high ICE (96.5% and 90.3%) and energy density (310 and 333Whkg-1). These findings present a facile and controllable pre-lithiation strategy to compensate for the lithium of LIBs, providing new valuable insights into the design and optimization of battery manufacture.

Dual Function of Hydrogen Bond and CEI to Enhanced Lithium-Ion Battery Performance.

The stability of the commercial electrolyte is linked to the internal solvent molecule, particularly in enhancing the stability of these molecules. Hereby, we introduce a dual function strategy involving hydrogen bond induced solvent molecules and the in situ fabrication cathode-electrolyte interphase (CEI) to address this issue. The additive N-(4-(2,5-dioxo-4-oxazolidinyl)butyl)-2,2,2-trifluoroacetamide (DOTFA), with its oxazolidinyl and trifluoroacetamide functional units, establishes hydrogen bonds with the solvent, forming CEI films on the cathode surface that enhance the antioxidation ability of the electrolyte. These hydrogen bonds contribute to enhancing the high-pressure structural stability of the solvent molecule. Additionally, the uniform and robust in situ constructed CEI films act as a shield, protecting the cathode from various side reactions and enhancing interface compatibility. By incorporation of the DOTFA additive in the electrolyte, lithium-ion batteries with NCM811 cathodes exhibit excellent cycling performance. The work highlights the significance of dual function in solvent molecules and provides an effective method for enhancing the antioxidation ability of the electrolyte.

Chelated Metal-Organic Frameworks for Improved the Performance of High-Nickel Cathodes in Lithium-Ion Batteries.

Lithium-ion batteries have gained widespread use in various applications, including portable devices, electric vehicles, and energy storage systems. High Ni cathode, LiNixCoyMnzO2 (NCM, x≥0.8, x+y+z=1), have garnered significant attention owing to their high energy density. However, the limited Li-ion transfer rate and transition metal cross-talk to anode pose obstacles to further improvement of electrochemical performance. To tackle these challenges, metal-organic frameworks (MOFs) with chelating agents are employed as additive materials for electrode. MOFs with chelating agents offer three key attributes: (1) Effective mitigation of transition metal cross-talk to the anode, (2) Partial desolvation of Li+ ions through MOF pores, and (3) Immobilization of anions via metal sites in the MOF. Leveraging these advantages, the chelating MOF-modified NCM cathode demonstrates reduced charge transfer resistance, both in their pristine and cycled states. In addition, they exhibit significantly improved the Li-ion diffusion coefficients after 100 cycles. These findings underscore the potential of MOFs with chelating agents as promising additive materials for enhancing the performance of LIBs.

Effective Upcycling of Degraded NCM Cathode Materials Assisted by Surface Engineering for High‐Performance Lithium‐Ion Batteries

AbstractLithium‐ion batteries (LIBs) with ternary oxide cathode materials are the prevalent energy storage devices for electric vehicles, and the huge amounts of spent LIBs pose severe challenges in terms of environmental impact and resource management. Particularly, the proper handling of degraded cathode materials is of central importance for the sustainable and closed‐loop development of LIBs industry. In this context, direct regeneration of degraded ternary oxides toward reusable high‐performance cathode materials is environmentally and economically favorable in contrast to present metallurgical recycling methods. In this work, a simple and effective two‐step method is demonstrated to regenerate the degraded NCM 622 (LiNi0.6Co0.2Mn0.2O2) materials by elemental compensation and structural restoration. Moreover, a multi‐functional LTO (Li4Ti5O12) surface coating is simultaneously designed to guarantee rapid Li+ diffusion and stable surface of the regenerated product. Therefore, the regenerated LTO‐coated NCM materials show excellent electrochemical performance; specifically, the initial discharge capacity (183.0 mAh g−1 at 0.1 C), rate capability (90.0 mAh g−1 at 10 C), and cycling stability (79.3% capacity retention after 200 cycles) are even comparable with those of fresh materials. The as‐established upcycling strategy may shed light on the value‐added recycling of degraded cathode materials and thereby a virtuous cycle of LIBs.

Regulating interfacial reactions via quasi-solid polymer electrolyte to enable high-voltage lithium metal batteries

Sulfolane (SUL), known for its low cost, environmental friendliness, and high voltage tolerance, stands out as a promising polar solvent for lithium (Li) metal batteries with high energy density. However, its long-term stability with Li metal is compromised due to its inherently low reduction resistance. To address this issue, we introduce a novel electrolyte strategy, where the reactive SUL is encapsulated within a fluorinated polymer framework formed through in-situ thermal polymerization. The polymer network’s specific structure interacts with SUL, effectively mitigating its electrochemical degradation on the Li metal anode and the NCM811 cathode, thus enhancing electrode stability. This approach not only extends the Li+ plating/stripping reversibility for over 1,000 h at a current density of 0.3 mA cm−2, but also delivers outstanding performance in NCM811||Li batteries, achieving a capacity retention of 78.56 % after 1,000 cycles at 30 °C and 87.14 % after 100 cycles at 60 °C under a high cutoff voltage of 4.5 V.

Insights into the Deterioration Mechanism of Charging Ability during Calendar Aging and Cycling Aging of High-Voltage Co-Poor NCM Cathode-Graphite Full Battery.

Lithium-ion battery (LIB) has gained significant recognition for the power cell market owing to its impressive energy density and appealing cost benefit. Among various cathodes, a high-voltage cobalt-poor lithium nickel manganese cobalt oxide cathode (Co-poor NCM cathode) has been considered as a promising strategy to enhance its energy density. Despite these advantages, high-voltage Co-poor NCM cathode-graphite full battery usually suffers from poor rate performance. However, fast charging has been a key indicator for widespread application of power batteries. Although many efforts have been made to improve the charging performance of fresh batteries, few works investigate the charging ability during calendar aging and cycling aging of high-voltage Co-poor NCM cathode-graphite full battery. In this work, we found that the charging ability becomes worse during calendar aging and cycling aging. Results showed that the increasing charge transfer resistance from the cathode is the major obstacle to achieving fast charging during the aging process. To address the problem, high-voltage Al2O3-coated Co-poor NCM cathode successfully prepared via a simple atomic layer deposition (ALD) method has been developed to reduce the decay of charging performance during calendar aging and cycling aging. Al2O3-coated NCM cathode can effectively reduce the growth rate of the resistance of cathode, which is benefiting from the conversion of Al2O3 into LiAlO2 with high ionic conductivity and the restriction formation of rock salt phase. Benefiting from the decreased charge transfer resistance of the NCM cathode, the mismatch of the lithium-ion reaction kinetics is well alleviated, thus effectively reducing the polarization under fast charging. As a result, Al2O3-coated NCM cathode-graphite full battery shows the slow deterioration of charging performance during the aging process. This work provides a promising strategy for constructing fast-charging batteries during calendar aging and cycling aging.

Enhanced cyclability and energy density of mid-nickel layered oxide cathode material LiNi0.55Mn0.25Co0.20O2 by niobium doping via solvothermal method

Ni-based layered oxide materials are among the most promising cathode materials for the next generation of lithium-ion batteries due to their higher energy capacity. However, capacity decay occurs due to degradation mechanisms that reduce the electrochemical performance of this type of material. This work aims to synthesize Nb-doped LiNi0.55Mn0.25Co0.20O2 (Nb-NCM) materials via the solvothermal method to enhance the cyclability and energy density of the layered oxide cathode. The effects of Nb doping on the microstructure and the electrochemical performance of the cathodes are investigated. The introduction of the contents of Nb expands the structural lattice parameters and decreases the Li+/Ni2+ cation mixing degree of the NCM cathode. Furthermore, the Nb doping enhances the electrochemical activity of LiNi0.55Mn0.25Co0.20O2, increasing its initial discharge capacity to 169.61 mAhg−1 when 1% of Nb was used as a dopant (1%Nb-NCM) in contrast to the capacity of 149.45 mAhg−1 presented by the pristine material. The modified 1.0%Nb-NCM material also exhibits remarkable cycling performance with a capacity retention of 92.7% after 100 cycles at the rate of 1 C (2.8–4.3 V). This work suggests a rational strategy for high-performance cathode for lithium-ion batteries, proposing the extension of Nb doping to enhance Ni-mid material's cyclability.

An artificial layer enables in situ generation of a homogeneous inorganic/organic composite solid electrolyte interphase for stable lithium metal batteries.

Lithium (Li) metal anodes are considered one of the most promising anodes for high-performance batteries with ultra-high specific energy density. However, uncontrolled dendrite growth and the unsuitability of common systems for high voltage hinder the development of Li metal batteries with long cycle life. Herein, we report a rationally designed artificial solid electrolyte interphase (SEI) for Li metal anodes, incorporating LiNO3 and lithium difluoro(oxalato)borate (LiDFOB) as additives within a porous poly (vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP) polymer skeleton (referred to as PNF). LiNO3 and LiDFOB can release and synergistically react at the electrode surface, leading to the in situ generation of a homogeneously distributed inorganic/organic SEI during the electrochemical process. This SEI improves homogeneity, ionic conductivity and mechanical stability, contributing to the suppression of electrolyte side reactions and Li dendrite growth. Moreover, a uniform CEI with high Li+ conductivity can be constructed on the NCM811 particles, further enhancing the structural integrity of the NCM811 cathode. As a result, the artificial SEI layer on Li metal anodes enables stable cycling of Li-Cu half cells in an ester-based electrolyte and Li-LiNi0.8Mn0.1Co0.1O2 full cell even at a high voltage of 4.5 V. This work provides new insights into designing homogeneous SEIs for Li metal batteries.

Effect of Conductive Carbon Morphology on the Cycling Performance of Dry-Processed Cathode with High Mass Loading for Lithium-Ion Batteries

The solvent-free dry processing of electrodes is highly desirable to reduce the manufacturing cost of lithium-ion batteries (LIBs) and increase the active mass loading in the electrode. The drying process is based on the fibrillation of the polytetrafluoroethylene binder induced by shear force. This technique offers the advantage of uniformly dispersing the active material and conductive carbon without binder migration, thereby facilitating the fabrication of thick electrode with high mass loading. In this study, we explored the influence of conductive carbon morphology on the cycling performance of dry-processed LiNi0.82Co0.10Mn0.08O2 (NCM) cathodes. In contrast to Super P, which provided electronic pathways through point-contact, the fibrous structure of the vapor-grown carbon fibers (VGCFs) promoted line-contact, ensuring long and less-torturous electronic pathways and enhanced utilization of active materials. Consequently, the cathode employing fibrous VGCFs achieved higher electrical conductivity, resulting in enhanced electrochemical performance. The dry-processed NCM cathode employing VGCF with an areal capacity of 8.5 mAh cm−2 delivered a high discharge capacity of 212 mAh g−1 with good capacity retention. X-ray photoelectron spectroscopy, X-ray diffraction, scanning electron microscopy, and transmission electron microscopy were conducted to investigate the degradation behavior of the high-mass-loaded cathodes with two different conductive carbons.

Reductive Dissolution of NCM Cathode through Anaerobic Respiration by Shewanella putrefaciens.

The consumption of lithium-ion batteries (LIBs) has considerably increased over the past decade, leading to a rapid increase in the number of spent LIBs. Exposing spent LIBs to the environment can cause serious environmental harm; however, there is a lack of experimentally obtained information regarding the environmental impacts of abandoned cathode materials. Here, we report the interactions between Shewanella putrefaciens, a microorganism commonly found in diverse low-oxygen natural settings, and LiNi0.6Co0.2Mn0.2O2 (NCM622) under anaerobic conditions. We present compelling evidence that the anaerobic respiration of Shewanella putrefaciens triggers ∼59 and ∼78% dissolution of 0.2 g/L pristine and spent NCM622, respectively. We observed that Shewanella putrefaciens interacted with the pristine and the spent NCM622 under anaerobic conditions at a neutral pH and room temperature and induced the reduction of Ni, Co, and Mn, resulting in the subsequent dissolution of Li, Ni, Co, and Mn. Moreover, we found that secondary mineralization occurred on the surface of reacted NCM622. These findings not only shed light on the substantial impact of microbial respiration on the fate of discarded cathode materials in anaerobic environments but also reveal the potential for sustainable bioleaching of cathodes in spent LIBs.

Constructing LiF‐Enriched Solid Electrolyte Interface on Graphene Arrays with Abundant Edges on Microscale Si‐C Anodes Toward High‐Energy Lithium‐Ion Batteries

AbstractSilicon (Si) anodes offer excellent lithium storage capacity for lithium‐ion batteries but face practical limitations due to significant volume expansion and low intrinsic electrical conductivity. These issues lead to side reactions that consume the electrolyte and impede ion‐electron transport, resulting in low areal loading (<2 mg cm⁻²) and restricted energy density. To address this, a scalable method is developed using spray drying of commercial graphite flakes (s‐Gr) and nanosilicon particles (n‐Si), followed by chemical vapor deposition to create microscale Si/C anodes (s‐Gr/n‐Si/VGs). Thin vertical graphene nanosheets (VGs) are grown on the surfaces and within the internal pores, forming a robust, micron‐sized Si/C spherical composite material. The VGs construct the conductive network, allowing the electrodes to operate at high areal loadings without pulverization and promoting LiF‐enriched solid electrolyte interphase for improved cycling stability. The s‐Gr/n‐Si/VGs maintain a capacity of 641.9 mAh g⁻¹ after 1000 cycles at 11.0 mg cm⁻², retaining 95.9% capacity. In pouch cells with NCM811 cathodes, the 5.0 Ah‐level cells achieved 80.0% capacity retention after 510 cycles at 1.0 C. This research provides a feasible pathway for manufacturing high‐performance, low‐cost, and scalable Si/C anodes suitable for high‐energy‐density lithium‐ion batteries.