Nickel-Cobalt Hydroxide Manufacturing via Segmented Precipitation
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Solution Overview
Problem
Conventional processes for manufacturing nickel-cobalt composite hydroxide struggle to achieve uniform particle diameter, leading to non-uniform voltages in electrodes and reduced battery performance due to mixed fine and coarse particles, and are limited by batch-type manufacturing inefficiencies.
Innovation Solution
A process involving a seed particle formation step with controlled nickel ion concentration and agitation, followed by a seed particle growth step with adjusted nickel ion concentration and pH, separates the formation of seed particles and their growth to achieve nickel-cobalt composite hydroxide with a narrow particle size distribution and uniform diameter, suitable for use in nonaqueous-electrolyte secondary batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional batch-type manufacturing processes are used for nickel-cobalt composite hydroxide, then manufacturing simplicity is maintained, but productivity is low and particle size uniformity is poor
Solution Approach 1:
The manufacturing process is segmented into distinct stages: nucleation phase with specific nickel ion concentration (0.1-5 ppm) to form uniform seed particles, followed by growth phase with higher nickel ion concentration (5-300 ppm) to develop particle size. This segmentation allows independent optimization of each phase to achieve both uniformity and productivity
Solution Approach 2:
Seed particles are formed in advance during the nucleation phase before the main growth phase begins. These pre-formed seeds provide a uniform foundation for subsequent particle growth, ensuring consistent particle size distribution while enabling continuous manufacturing processes
2Manufacturing precision
If nickel ion concentration is not controlled during particle formation, then manufacturing process is simpler, but particle size distribution becomes wide and non-uniform
Solution Approach 1:
Nickel ion concentration is changed at specific stages: maintained at 0.1-5 ppm during nucleation to control seed formation, then increased to 5-300 ppm during growth phase to control particle size development. This parameter change strategy achieves precise particle size control through systematic concentration management rather than complex multi-variable control
3Manufacturing precision
If seed particle formation and growth occur simultaneously, then manufacturing process is shorter, but particle size distribution becomes wide due to mixed fine and coarse particles
Solution Approach 1:
The process separates particle formation into distinct nucleation and growth phases occurring in sequence rather than simultaneously. The nucleation phase creates uniform seeds first, then the growth phase uniformly enlarges them, preventing the formation of mixed-size particles while maintaining efficient continuous operation
Solution Approach 2:
Seed particles are preliminarily formed with controlled size and distribution before the main growth phase. This preliminary action establishes a uniform particle population that grows consistently during the subsequent phase, achieving narrow size distribution without requiring extended processing time
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 results in a nickel-cobalt composite hydroxide with a narrow particle size distribution and uniform diameter, enhancing battery performance and allowing for high productivity through continuous manufacturing.
Implementation Method 1
a process involving a seed particle formation step with controlled nickel ion concentration and agitation, followed by a seed particle growth step with adjusted nickel ion concentration and pH
Data Source
AI summary
Process for manufacturing nickel-cobalt composite represented by Ni1−x−yCoxMnyMz(OH)2 (where, 0.05≦x≦0.95, 0≦y≦0.55, 0≦z≦0.1, x+y+z<1, and M is at least one metal-element selected from Al, Mg, and the like), includes: forming seed particle, while reaction solution having mixed solution containing metal compounds and ammonia solution containing ammonium ion supply source at discharge head of an impeller from 50-100 m2/s2, the concentration of nickel ions is maintained within range 0.1-5 ppm by mass, whereby seed particles are formed; and growing seed particle wherein solution is obtained by supplying mixed and ammonium solutions to reaction solution is agitated with a concentration of nickel ions being maintained within range 5-300 ppm by mass and higher than the concentration of nickel ions in seed particle formation, whereby seed particles are grown up.