Development of nickel rich and concentration gradient cathode materials for high energy density and long cycle-life lithium ion batteries using controlled micro-aerosol pyrolysis

Lithium ion batteries (LIBs) are promising candidates for next-generation energy storage and electrified transportation systems. However, continuous growth of cobalt price, low energy density, short lifetime, and high propensity in fire accidents of LIBs creates a big challenge to renewable electricity production and electrification of transportation. Therefore, there is an urgent need to develop low cost, high energy density, long cycling, and fire resistant LIBs cathode materials for the integration of renewable energy, energy storage, electrification of transportation, and smart mobility. In this project, a new type of controlled micro-aerosol pyrolysis process will be explored for the synthesis of high nickel and concentration-gradient cathode materials that will systematically improve the electrochemical performance of lithium ion batteries, reduce chemical footprint and fire propensity, and strongly promote the utilization of renewable energy for transportation and high efficient energy storage. This Small Business Innovation Research Phase I project will develop a novel micro-aerosol and controlled high temperature (MACHT) evaporation and pyrolysis process for the synthesis of high nickel content nickel-cobalt-manganese (NCM) high-energy cathode materials using particle morphology control, concentration gradient, and precision ion-doping. By controlling the ratio of solvent evaporation time to precursor diffusion time during heating, a uniform high nickel content nanoparticle morphology is achieved which increases the energy density of LiB. The concentration gradients of nickel and doped ions, which significantly increases the LiBs cycling performance and fire resistance, are realized from the differences in precursor solubility and precipitation rate. Thus, MACHT provides a new way to precisely control nanoparticle morphology, precision ion doping and functional ion gradients to design new and advanced NCMs and nickel-cobalt-alumina NCA cathode materials for LiBs. Compared to commercial co-precipitation methods, MACHT process has the potential to significantly lower the manufacturing costs, increase the energy density and battery cycling performance, and reduce fire propensity and chemical waste production, offering the great opportunity to advance the discovery of new high performance battery materials. The success of this technology will greatly enhance the overall performance of lithium-ion batteries to meet energy density, power, lifetime, and fire safety objectives. The development of the advanced cathode materials by using the proposed technology will increase the commercial viability of LIBs and reduce battery cost, and thus accelerates the electrification of transportation and large scale energy storage for renewable energy in the near future. Moreover, MACHT technology is transformative. If successful, it will create a new LiBs cathode materials manufacture process and establish the leadership of US manufactures of LiBs. In addition, MACHT increases recycling ability of key materials in battery (lithium, cobalt and nickel), eliminates the production of large amount of waste in existing commercial co-precipitation method, and reduces the propensity of fire accidents. Furthermore, MACHT method can also be used for synthesis of other nanomaterials for energy storage, catalysis, and biomedical applications to control nanoparticle morphology and functionality. As such, the proposed project will have large impact on the US economics and job employment. Finally, the project will provide hands on experiences for high school and minority students to design EV batteries.