R&D Projects in Battery Materials and Component Processing

R&D Projects in Battery Materials and Component Processing Science & Engineering

Peter Faguy Batteries and Electrification, Vehicle Technologies Office

June 23, 2021 VTO AMR BAT474

2U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY

Processing Science & Engineering R&D to Improve Production

Cell-level FoMs:

specific energy cycle life fast charging thermal and abuse

stability calendar life

materials

processing

Process FoMs:

volume-at-scale flexible optimizable sustainable

possible

high performing, well-characterized

high volume, reproducible

Bench Scale Pre-pilot Pilot Manufacturing


Processing Science

Morphological changes show a strong temperature dependence.

Lithiation driven particle swelling

Growth of larger particles at the expense of the smaller ones

800ºC(~ 20 hr) 850ºC(~10 hr)Initial 900ºC(~10 hr)

Sintering at intermediate temperatures shows a strong dependence on surface oxygen.

Conventional Pre-converted

Rapid sintering of both pre-converted and conventional precursors > 600ºC

O2 surface coverage inhibits sintering of pre-converted samples

BAT #402 Multiscale simulation

BAT #183 Experiment

Modeling and in situ characterization of NMC811 during calcination


Processing Engineering

Lithium metal deposition

Anode Manufacturing through Ultra-Thin Li Deposition (BAT495)

Thin-Film Lithium Metal Manufacture by Room Temperature Electrodeposition (BAT522)


FY2021 Annual Merit Review Presentations: Oral

VTO Battery Processing Science and Engineering Projects

Date Time Project ID, Title, PI, Organization

Wed. June 23, 2021 10:00 AM BAT474: R&D Projects in Battery Materials and Component Processing Science & Engineering, Peter Faguy, DOE

Wed. June 23, 2021 10:30 AM BAT030: Electrode Prototyping Activities in ANL's Cell Analysis, Modeling and Prototyping (CAMP) Facility, Steve Trask, ANL

Wed. June 23, 2021 11:00 AM BAT232: High Energy Density Electrodes via Modifications to the Inactive Components and Processing Conditions; Vincent Battaglia, LBNL

Wed. June 23, 2021 11:30 AM BAT164: Thick, Low-Cost, High-Power Lithium-Ion Electrodes via Advanced Processing, Jianlin Li, ORNL

Wed. June 23, 2021 12:00 PM BAT475: Towards Solventless Processing of Thick Electron- Beam (EB) Cured Lithium-Ion Battery Cathodes, Zhijia Du, ORNL

Wed. June 23, 2021 1:40 PM BAT476: Establishing Materials and Component Testing Protocols, Adam Tornheim, ANL

Wed. June 23, 2021 2:10 PM BAT168: Process Development and Scale-Up of Critical Battery Materials - Continuous Flow-Produced Materials, Krzysztof Pupek, ANL

Wed. June 23, 2021 2:40 PM BAT315: Process R&D for Droplet-Produced Powdered Materials, Joe Libera, ANL

Wed. June 23, 2021 3:45 PM BAT167: Process Development and Scale-Up of Advanced Active Battery Materials, Ozge Kahvecioglu, ANL

Wed. June 23, 2021 4:15 PM BAT470: Process R&D Using Supercritical Fluid Reactors, Youngho Shin, ANL

All FFRDC Lab Call ProjectsProcSciEng under review

Supporting all FFRDC programs, FCAB


FY2021 Annual Merit Review Presentations: Posters

VTO Battery Processing Science and Engineering Projects

Date Time Project ID, Title, PI, Organization

Fri. June 25, 2021 11 AM-1 PM BAT028: Materials Benchmarking Activities for Cell Analysis, Modeling, and Prototyping (CAMP) Facility, Wenquan Lu, ANL

Fri. June 25, 2021 11 AM-1 PM BAT522: Thin-film Lithium Metal Manufacture by Room Temperature Electrodeposition, Alirio Liscano, Albemarle

Fri. June 25, 2021 11 AM-1 PM BAT495: Anode Manufacturing through Ultra-Thin Li Deposition, Subra Herle, Applied Materials

Fri. June 25, 2021 11 AM-1 PM BAT183: In Situ Spectroscopies of Processing Next-Generation Cathode Materials, Feng Wang, BNL

Fri. June 25, 2021 11 AM-1 PM BAT269: An Integrated Flame-Spray Process for Low-Cost Production of Battery Materials, Chad Xing, Univ. of Missouri

Fri. June 25, 2021 11 AM-1 PM BAT402: Improving Battery Performance through Structure-Morphology Optimization, Venkat Srinivasan, ANL

ProcSciEng under review

FOA projects


EERE Advanced Li-ion Battery Manufacturing Commitments

EERE OfficeAMO 18VTO 6

Funding Mechanism FOA 2019 11

Lab Call 2020 13

Cell ChemistryNG LiBs 16Li-based 2ASSB 5

R&D Focus Electrode/Electrolyte Processing 13

Materials Processing 11

ComponentCathode 12Anode 3Electrolyte 7Separator/Current Collector 2

FY2019 AMO FOA & FY2020 BatMan Lab Call Projects

$66.2M DOE funds, $38.8M cost share

Project Title Lead Org. Partner(s) Main Focus

Enabling Advanced Electrode Architecture through Printing Technique

WMU WMU; ANL ; BrownU; NEU; UNCCharlotte; Nanoramic Labs; SafeSense Tech.

Electrode Processing

High Throughput Solvent-free Manufacturing of Battery Electrodes

Navitas Arkema; Cabot; ORNL; UTennKnoxville

Electrode Processing

Scale-up Production of Graphene Monoxide for Next-Generation LIB Anodes

ANL Connovate Materials Processing

Hydrothermal Production of Single Crystal Ni-rich Cathodes with Extreme Rate Capability

ANL Hunt Energy Materials Processing

Scaling up of High-Performance Single Crystalline Ni-rich Cathode Materials with Advanced Lithium Salts

PNNL Albemarle Materials Processing

Some examples


Where to focus for cost reduction ?

SOURCE:AVICENNE ENERGY 2019

ADEME-BpifranceBattery Storage Meeting

Paris, France May 28, 2019

Cathode active materials and cell manufacturingaccount for the two largest cost segments in LiB pack production.

For 2025, AvicenneEnergy estimates both segments will cost ~30% of a $135/kWh pack.

LiB cell average cost (40Ah pouch) (EV design; NMC 622 CAM)

LI-ION BATTERY COST 2018 – 2025

(1) active materials only

LiB Pack Cost for EV (2)

(2) for production > 100,000 packs/year


Breakdown of manufacturing costs at the cell level – graphite | NMC111 cells in 37 Ahr cell.

Some processing costs imbedded

Why Fund Processing Science & Engineering ?

Kwade et al “Current status and challenges for automotive battery production technologies”Nature Energy 290(3); 2018 pp. 290–300 https://doi.org/10.1038/s41560-018-0130-3

Manufacturing costs (%)

All processing costs


Next-Generation Cathode Materials and Cathode/Electrolyte Interfaces

• Cathode active materials (CAMs) containing Ni, Co, Mn, Fe and other transition metals will dominate all Li-based battery technologies for the next 6+ years.

• Reducing Co content and improving performance and safety of high Ni CAMs and lowering processing costs are key objectives of this R&D portfolio.

• From 2016 to present the portfolio averaged 15.5 projects annually with a total DOE investment of over $80M.

20 posters for the 2021 AMR from project teams that include academia, industry and the national labs.

Live Poster Q&A Sessions Friday, June 25, 11am-1pm ET


Peter [email protected]

QUESTIONS ... COMMENTS ... SUGGESTIONS ... ????

R&D Projects in Battery Materials and

Component Processing Science & Engineering

Vehicle Technologies Office Annual Merit Review, June 2021

Documents

R&D Projects in Battery Materials and Component Processing