Periodic Reporting for period 1 - HELENA (Halide solid state batteries for ELectric vEhicles aNd Aircrafts)
Reporting period: 2022-06-01 to 2023-11-30
The next generation in electric vehicle batteries will probably see the replacement of lithium-ion batteries with higher-performing alternatives. It is therefore crucial to develop different types of solid-state batteries to fulfil the growing energy density requirements. Generation 4b batteries have higher energy densities and longer ranges. The EU-funded HELENA project will respond to the need for a safe, high energy efficiency solid-state battery cell. Researchers are looking to produce a Generation 4b battery with a high-energy density lithium metal anode, a nickel-rich nickel–manganese–cobalt cathode and a superionic halide solid electrolyte. Project activities should enable low-cost, scalable and safe cell manufacturing and fast battery charging, thereby boosting the electric vehicles’ driving range.
The HELENA project was developed in the first 18 months, in general terms on schedule and no significant deviations were found in any of the WPs or tasks that were developed. The present report describes in detail all the results obtained as well as all the deviations from the technical and the financial point of view.
As a general overview of the project’s status, all work packages are progressing smoothly towards established goals, aligning with the predefined phases and schedule. Additionally, there are promising perspectives on the scientific and technological advancements achieved up to date.
Summarizing the contributions to RP1 from the technical work packages, WP2 has defined requirements for electric vehicles and aeronautical applications, establishing concise testing protocols for evaluating battery cell performance under various conditions.
WP3 has successfully delivered different generations of halide electrolytes to the consortium, reaching the KPI targets. Initial sampling of high-voltage active material (NMC622) has been sourced for lab-scale cell assembly. Li metal benchmarking has been conducted, and Li on Cu was distributed among partners for electrochemical testing. Ongoing efforts in WP3 involve the development of protective layers with challenges already identified.
WP4 has made significant progress in the electrochemical characterization of materials sourced from WP3, assembling high-loading full lab-scale cells with NMC622 and Li metal. Investigations on the halide/Li metal interface led to a potential product-by-process industrial property. WP4 is transitioning towards the fabrication of battery components compatible with upscaling methods.
WP5 focuses on large-scale production of cathode/electrolyte bilayers and prototype cell assembly. Although this work package has not begin, essential inputs from other WPs are being gathered to anticipate WP5 tasks.
Within WP6, testing protocols for electric vehicle and aeronautic use-cases have been defined in alignment with WP2 and incorporating specific needs for model validation in WP7. In the modeling activities, a multiphysics/multiscale approach has been defined, and interfaces between different scale models have been established in WP7, with promising preliminary results in developing atomistic- and particle-based physical models.
Finally, WP8 has formulated a recycling experimental strategy plan for HELENA cells, based on recycling concepts for advanced energy storage systems.
HELENA is now approaching the cell scaling phase. All WPs have identified potential risks, especially during the challenging transition from lab-scale to pouch cell. These risks are under control, with specific mitigation plans in place to avoid deviations and ensure the successful achievement of established goals.
As a general overview of the project’s status, all work packages are progressing smoothly towards established goals, aligning with the predefined phases and schedule. Additionally, there are promising perspectives on the scientific and technological advancements achieved up to date.
Summarizing the contributions to RP1 from the technical work packages, WP2 has defined requirements for electric vehicles and aeronautical applications, establishing concise testing protocols for evaluating battery cell performance under various conditions.
WP3 has successfully delivered different generations of halide electrolytes to the consortium, reaching the KPI targets. Initial sampling of high-voltage active material (NMC622) has been sourced for lab-scale cell assembly. Li metal benchmarking has been conducted, and Li on Cu was distributed among partners for electrochemical testing. Ongoing efforts in WP3 involve the development of protective layers with challenges already identified.
WP4 has made significant progress in the electrochemical characterization of materials sourced from WP3, assembling high-loading full lab-scale cells with NMC622 and Li metal. Investigations on the halide/Li metal interface led to a potential product-by-process industrial property. WP4 is transitioning towards the fabrication of battery components compatible with upscaling methods.
WP5 focuses on large-scale production of cathode/electrolyte bilayers and prototype cell assembly. Although this work package has not begin, essential inputs from other WPs are being gathered to anticipate WP5 tasks.
Within WP6, testing protocols for electric vehicle and aeronautic use-cases have been defined in alignment with WP2 and incorporating specific needs for model validation in WP7. In the modeling activities, a multiphysics/multiscale approach has been defined, and interfaces between different scale models have been established in WP7, with promising preliminary results in developing atomistic- and particle-based physical models.
Finally, WP8 has formulated a recycling experimental strategy plan for HELENA cells, based on recycling concepts for advanced energy storage systems.
HELENA is now approaching the cell scaling phase. All WPs have identified potential risks, especially during the challenging transition from lab-scale to pouch cell. These risks are under control, with specific mitigation plans in place to avoid deviations and ensure the successful achievement of established goals.
Expected impact 1: European battery value chain capability
HELENA will contribute to this goal through the development of an innovative halide-based 4b generation batteries for electromobility. Key partners in the EU industry are actively contributing to the project by supplying essential materials for the battery industry. This demonstrates the value chain's robustness and underscores the leadership of EU stakeholders in the sector. Notably, materials sourced from HELENA are entirely produced within Europe, with the exception of Li metal. This strategic sourcing approach minimizes dependence on non-EU competitors, highlighting Europe's capability to achieve independence from external influences.
Expected impact 2: Batteries of generation 4b with high energy capacity and high voltage stability
HELENA will fulfill this outcome by using Ni-rich NMC high-voltage active material with halide solid electrolyte and Li metal anode. The consortium has successfully procured NMC and halide electrolyte for the project. Initial coin cells of high-capacity with loadings of up to 4 mAh/cm2, have been manufactured using NMC622, halide electrolyte, and thin, unprotected Li metal. The outcomes of these lab-scale cell experiments showcase the considerable potential and promising prospects for this technology. The dissemination of these results will capture the attention of the scientific community, battery manufacturers, and stakeholders in the automotive and aerospace sectors.
Expected impact 3: Sustainable and safety advanced Li-on batteries for electro mobility sector, especially in aircraft and EV
Within HELENA, the battery cells that will be designed, developed, and manufactured will aim to power electric and hybrid electric aircraft as well as to upscale it for other potential sectors as automotive as EVs applications. Pre-industrial prototypes have not yet been produced in Helena. However, the main contribution towards EV and aeronatic applications during PR1 lies on the definition of automotive and aeronautic consolidated requirements.
Expected impact 4: Halide-based Solid-State cell technology for cost-competitive large-scale manufacturing
HELENA envisions to produce affordable, high performance and safe batteries that can compete with the best-inclass incumbent aircrafts and ICE vehicles. During PR1 partners sourcing key materials such as halides and active materials have developed a series of generations with not only improved properties for the battery application but also considering lowering the manufacturing costs. Specific manufacturing tasks like extrusion of the components have already started being assessed in the project to reduce costs by decreasing process time and the solvent volume.
Expected impact 5: - HELENA project will support the change of paradigm of transport field into a more sustainable one towards climateneutral by 2050
During PR1 partners working on the recyclability of the final battery developed have been started to design recycling pathways considering materials and processes of the proposed technology.
HELENA will contribute to this goal through the development of an innovative halide-based 4b generation batteries for electromobility. Key partners in the EU industry are actively contributing to the project by supplying essential materials for the battery industry. This demonstrates the value chain's robustness and underscores the leadership of EU stakeholders in the sector. Notably, materials sourced from HELENA are entirely produced within Europe, with the exception of Li metal. This strategic sourcing approach minimizes dependence on non-EU competitors, highlighting Europe's capability to achieve independence from external influences.
Expected impact 2: Batteries of generation 4b with high energy capacity and high voltage stability
HELENA will fulfill this outcome by using Ni-rich NMC high-voltage active material with halide solid electrolyte and Li metal anode. The consortium has successfully procured NMC and halide electrolyte for the project. Initial coin cells of high-capacity with loadings of up to 4 mAh/cm2, have been manufactured using NMC622, halide electrolyte, and thin, unprotected Li metal. The outcomes of these lab-scale cell experiments showcase the considerable potential and promising prospects for this technology. The dissemination of these results will capture the attention of the scientific community, battery manufacturers, and stakeholders in the automotive and aerospace sectors.
Expected impact 3: Sustainable and safety advanced Li-on batteries for electro mobility sector, especially in aircraft and EV
Within HELENA, the battery cells that will be designed, developed, and manufactured will aim to power electric and hybrid electric aircraft as well as to upscale it for other potential sectors as automotive as EVs applications. Pre-industrial prototypes have not yet been produced in Helena. However, the main contribution towards EV and aeronatic applications during PR1 lies on the definition of automotive and aeronautic consolidated requirements.
Expected impact 4: Halide-based Solid-State cell technology for cost-competitive large-scale manufacturing
HELENA envisions to produce affordable, high performance and safe batteries that can compete with the best-inclass incumbent aircrafts and ICE vehicles. During PR1 partners sourcing key materials such as halides and active materials have developed a series of generations with not only improved properties for the battery application but also considering lowering the manufacturing costs. Specific manufacturing tasks like extrusion of the components have already started being assessed in the project to reduce costs by decreasing process time and the solvent volume.
Expected impact 5: - HELENA project will support the change of paradigm of transport field into a more sustainable one towards climateneutral by 2050
During PR1 partners working on the recyclability of the final battery developed have been started to design recycling pathways considering materials and processes of the proposed technology.