Strength Deterioration of Nonfractal Particle Aggregates in Simple Shear Flow

Method for predicting the size of Ni1/3Mn1/3Co1/3(OH)2 particles precipitated in a stirred-tank semi-batch crystallizer using CFD and particle agglomeration models

NixMnyCoz(OH)2 is widely used as a precursor for the cathode active material LiNixMnyCozO2 in lithium ion batteries, and the precursor size, which determines the size of the active cathode material, affects the characteristics of lithium-ion batteries. This paper proposes a method for predicting the particle size of Ni1/3Mn1/3Co1/3(OH)2 precipitated by semi-batch reaction crystallization. The distribution of supersaturated components formed in the reactor varies with the reactor scale, feed conditions of the raw material solution, and agitation conditions. Therefore, the method presented in this paper considers the effects of these conditions on particle growth. First, to identify the turbulent dispersion and concentration distribution of the supersaturated components formed in the reaction crystallizer, a computational fluid dynamics (CFD) model was constructed consisting of the governing equations of hydrodynamics and the mass balance equations of the supersaturated components considering the production by neutralization and consumption by precipitation. Next, a model of agglomeration was constructed that focused on the balance of the binding and breaking up energies for the particle pairs. The binding energy was quantified based on the bridging between particle pairs by surface deposition. The breaking up-energy was quantified based on the hydrodynamic forces when the agglomerate passes through the impeller. These models were fitted using experimental results for the final average size of the Ni1/3Mn1/3Co1/3(OH)2 secondary aggregate, which was precipitated in a small-scale stirred-tank type semi-batch reaction crystallizer. The models predicted the experimental results of the final average size in a large-scale crystallizer, with the feeding conditions of the raw material solution and stirring conditions as experimental parameters, within ±20%. The models may be used to analyze semi-batch reaction crystallization systems of NixMnyCoz(OH)2 of any composition by adjusting the model parameters according to the procedure developed in this study.

Role of Flow Inertia in Aggregate Restructuring and Breakage at Finite Reynolds Numbers

Forces acting on aggregates depend on their properties, such as size and structure. Breakage rate, stable size, and structure of fractal aggregates in multiphase flows are strongly related to the imposed hydrodynamic forces. While these forces are prevalently viscous for finite Reynolds number conditions, flow inertia cannot be ignored, thereby requiring one to fully resolve the Navier-Stokes equations. To highlight the effect of flow inertia on aggregate evolution, numerical investigation of aggregate evolution in simple shear flow at the finite Reynolds number is conducted. The evolution of aggregates exposed to shear flow is tracked over time. Particle coupling with the flow is resolved with an immersed boundary method, and flow dynamics are solved using a lattice Boltzmann method. Particle dynamics are tracked by a discrete element method, accounting for interactions between primary particles composing the aggregates. Over the range of aggregate-scale Reynolds numbers tested, the breakage rate appears to be governed by the combined effect of momentum diffusion and the ratio of particle interaction forces to the hydrodynamic forces. For higher shear stresses, even when no stable size exists, breakage is not instantaneous because of momentum diffusion kinetics. Simulations with particle interaction forces scaled with the viscous drag, to isolate the effect of finite Reynolds hydrodynamics on aggregate evolution, show that flow inertia at such moderate aggregate Reynolds numbers has no impact on the morphology of nonbreaking aggregates but significantly favors breakage probability. This is a first-of-its-kind study that establishes the role of flow inertia in aggregate evolution. The findings present a novel perspective into breakage kinetics for systems in low but finite Reynolds number conditions.

Numerical investigation of the respective roles of cohesive and hydrodynamic forces in aggregate restructuring under shear flow

HYPOTHESIS

Aggregate structure is conditioned by a balance of cohesive forces between primary particles and hydrodynamic forces induced by the surrounding flow. Numerical simulations for different ratios between radial and tangential components of cohesive forces to hydrodynamic forces should highlight the role of the each force in aggregate restructuring under shear flow.

EXPERIMENTS

Aggregates sharing similar morphological characteristics were algorithmically created. The forces between primary particles were accounted for using models taken from the literature. Aggregates with different cohesive forces were then submitted to shear by imposing a shear stress in the liquid phase. Hydrodynamic forces were calculated following two approaches: first, with a free draining approximation to extract general trends, then with immersed boundaries in a lattice Boltzmann flow solver to fully resolve the flow and particle dynamics.

FINDINGS

Aggregate structural changes were tracked over time and their stable final size, or eventual breakage, was recorded. Their final structure was found to depend little on normal cohesive forces but is strongly impacted by tangential forces. Normal forces, however, strongly affect breakage probability. Furthermore, resistance to deformation at the aggregate scale induces a flow disturbance that reduces drag forces compared to the free-draining approximation, significantly impacting aggregate restructuring.