Ni-Co-Mn Hydroxide Precursors With Narrow Particle Size Control
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Solution Overview
Problem
Current methods for producing cathode materials for lithium-ion batteries result in precursors with irregular particle shapes and wide particle size distributions, which negatively impact the performance and longevity of the batteries.
Innovation Solution
A multi-step process involving the combination of aqueous solutions containing nickel and transition metal salts with alkali metal hydroxide and ammonia, under controlled pH conditions in stirred tank reactors, to produce highly spherical particulate (oxy)hydroxides with narrow particle size distributions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional co-precipitation methods are used to produce precursor materials, then the manufacturing process is simple, but the particle size distribution is wide and particle shape is irregular
Solution Approach 1:
The precipitation process is divided into two distinct stages: a continuous precipitation stage followed by a batch-wise precipitation stage. This segmentation allows each stage to be optimized independently - the continuous stage controls initial particle formation and the batch stage refines the final particle size distribution, achieving narrow distribution without excessive overall complexity
Solution Approach 2:
The continuous precipitation stage performs preliminary particle formation and size control before the batch-wise stage completes the process. By establishing controlled nucleation and growth conditions in advance, the method pre-determines much of the final particle size distribution, reducing the need for complex post-processing
2Shape
If conventional co-precipitation methods are used, then the process is straightforward, but the precursor sphericality is low
Solution Approach 1:
The method employs dynamic control of pH conditions throughout the precipitation process, adjusting pH values at different stages (higher pH in continuous stage, lower pH in batch stage). This dynamic pH control influences particle growth patterns to favor spherical morphology while maintaining manufacturing feasibility through systematic parameter adjustment
3Reliability
If thermal treatment is performed at high temperatures to form electrode active material, then the reaction is complete, but energy consumption is high
Solution Approach 1:
The method optimizes thermal treatment parameters including temperature, time, and atmosphere to achieve complete reaction at reduced energy input. By carefully controlling these parameters and using the pre-formed spherical precursor structure, the process achieves reliable conversion to electrode active material with improved energy efficiency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process yields precursors with favorably oriented primary particles, leading to high-density materials that improve the charge density, specific energy, and cycle life of lithium-ion batteries.
Implementation Method 1
combining a solution (α) and a solution (β) and, if applicable, a solution (γ) at a pH value in the range of from 12.0 to 13.0 determined at 23° C. in a continuous stirred tank reactor, thereby creating solid particles of a hydroxide containing nickel
Data Source
AI summary
Disclosed herein is a method for making a particulate (oxy)hydroxide of TM, where TM is a combination of nickel and at least one metal selected from Co and Mn, the process including:(a) providing an aqueous solution (α) containing water-soluble salts of Ni and of at least one transition metal selected from Co and Mn,(b) combining a solution (α) and a solution (β) and, if applicable, a solution (γ) at a pH value in a range of from 12.0 to 13.0 determined at 23° C. in a continuous stirred tank reactor, thereby creating a slurry of solid particles of a hydroxide containing nickel, and(c) transferring slurry from step (b) into a batch-wise operated stirred tank reactor where a solution (α) and a solution (β) and optionally a solution (γ) are combined with the slurry at a pH value in a range of from 11.0 to 12.0 determined at 23° C.