Efficient Production of Low-cost Battery Electrode Materials

Rechargeable lithium ion batteries (LIBs) are now one of the major power storage solutions; they are used in portable electronics, electric vehicles and renewable energy storage systems. Many weapons now depend on LIBs to power their systems. Unfortunately, the US military is particularly vulnerable to supply shortages of the active components needed for LIBs because virtually all large-scale production of electrode materials is done outside the US. In addition, may types of LIBs also incorporate cobalt. Cobalt is expensive, the supply is limited, and shortages are expected. As a result, there is a great need for cathode materials that are cobalt free, readily available in the US and that are safe and inexpensive.   The technical objective of the project is to develop an efficient low-cost method for producing large quantities of high-quality lithium iron phosphate (LFP). To accomplish this objective, we will develop a continuous production process. We will evaluate the LFP cathode materials by characterizing their physical and chemical structures and evaluate their electrochemical performance in the battery coin cells. We will estimate the total costs (materials, capital equipment) of our LFP production process. Based on this analysis, we will design and build a continuous pilot-scale production process for LFP in Phase II.