A Fast Approach to Obtain Layered Transition-Metal Cathode Material for Rechargeable Batteries

Synthesis and Characterisation of Core-Shell Microparticles Formed by Ni-Mn-Co Oxides

In this work, core and core-shell microparticles formed by Ni-Mn-Co oxides with controlled composition were fabricated by an oxalate-assisted co-precipitation route, and their properties were analysed by diverse microscopy and spectroscopy techniques. The microparticles exhibit dimensions within the 2-6 μm range and mainly consist of NiO and NiMn2O4, the latter being promoted as the temperature of the treatment increases, especially in the shell region of the microparticles. Aspects such as the shell dimensions, the vibrational modes of the spinel compounds primarily observed in the shell region, the oxidation states of the cations at the surface of the microparticles, and the achievement of a Ni-rich 811 core and a Mn-rich 631 shell were thoroughly evaluated and discussed in this work.

Slug Flow Coprecipitation Synthesis of Uniformly-Sized Oxalate Precursor Microparticles for Improved Reproducibility and Tap Density of Li(Ni0.8Co0.1Mn0.1)O2 Cathode Materials

The microparticle quality and reproducibility of Li(Ni_0.8Co_0.1Mn_0.1)O₂ (NCM811) cathode materials are important for Li-ion battery performance but can be challenging to control directly from synthesis. Here, a scalable reproducible synthesis process is designed based on slug flow to rapidly generate uniform micron-size spherical-shape NCM oxalate precursor microparticles at 25-34 °C. The whole process takes only 10 min, from solution mixing to precursor microparticle generation, without needing aging that typically takes hours. These oxalate precursors are convertible to spherical-shape NCM811 oxide microparticles, through a preliminary design of low heating rates (e.g., 0.1 and 0.8 °C/min) for calcination and lithiation. The outcome oxide cathode particles also demonstrate improved tap density (e.g., 2.4 g mL^-1 for NCM811) and good specific capacity (202 mAh g^-1 at 0.1 C) in coin cells and reasonably good cycling performance with LiF coating.

Scalable Advanced Li(Ni0.8Co0.1Mn0.1)O2 Cathode Materials from a Slug Flow Continuous Process

Li[Ni_0.8Co_0.1Mn_0.1]O₂ (LNCMO811) is the most studied cathode material for next-generation lithium-ion batteries with high energy density. However, available synthesis methods are time-consuming and complex, restricting their mass production. A scalable manufacturing process for producing NCM811 hydroxide precursors is vital for commercialization of the material. In this work, a three-phase slug flow reactor, which has been demonstrated for its ease of scale-up, better synthetic control, and excellent uniform mixing, was developed to control the initial stage of the coprecipitation of NCM811 hydroxide. Furthermore, an equilibrium model was established to predict the yield and composition of the final product. The homogeneous slurry from the slug flow system was obtained and then transferred into a ripening vessel for the necessary ripening process. Finally, the lithium-nickel-cobalt-manganese oxide was obtained through the calcination of the slug flow-derived precursor with lithium hydroxide, having a tap density of 1.3 g cm^-3 with a well-layered structure. As-synthesized LNCMO811 shows a high specific capacity of 169.5 mAh g^-1 at a current rate of 0.1C and a long cycling stability of 1000 cycling with good capacity retention. This demonstration provides a pathway toward scaling up the cathode synthesis process for large-scale battery applications.