Periodic Reporting for period 1 - OxyBatt (High-temperature oxygen batteries for Industrial Internet of Things)
Reporting period: 2024-05-01 to 2025-04-30
As industries strive for greater performance and efficiency, they are undergoing a transformative shift marked by the integration of connectivity, real-time adaptability, and tightly controlled production processes. At the forefront of this transformation is the Industry 4.0 model, which introduces advanced levels of cognitive automation. A central goal of this model is the implementation of predictive maintenance strategies aimed at minimizing equipment failures, reducing downtime, and lowering maintenance costs. This transition is driving a market expected to grow eightfold over the next seven years.
At the core of Industry 4.0 lies the collection and analysis of data generated by equipment and production processes. This is made possible through the widespread deployment of sensors, communication systems, and control units—together forming the Industrial Internet of Things (IIoT). The value of this data is maximized when it is gathered in real time and directly from the production line. Thanks to ongoing technological progress, it is now feasible to monitor key parameters even in extreme conditions involving intense vibrations, chemical exposure, humidity, or radiation.
Yet, a major challenge remains unsolved: there is currently no battery capable of reliably powering IIoT devices at temperatures between 200 °C and 400 °C.
While this might appear to be a specialized concern, it has far-reaching implications. Globally, thousands of companies—worth billions of euros—operate in sectors such as iron and steel production, cement, chemicals, and petrochemicals, where processes frequently occur within this high-temperature range. These industries are actively seeking affordable and robust solutions for process monitoring, shifting from reactive and scheduled maintenance to preventive strategies. However, this shift is severely limited by a significant technological barrier: at elevated temperatures, conventional batteries suffer from material degradation, heat buildup, self-discharge, and the risk of thermal runaway. These issues make existing battery technologies unsuitable for high-temperature environments, effectively blocking the adoption of critical IIoT advancements.
The OxyBatt project directly addresses this gap by developing a secondary battery system capable of operating safely and reliably within the 200 °C to 400 °C range. The OxyBatt solution offers intrinsic safety and long-term stability, paving the way for reliable power storage in extreme industrial settings.
At the core of Industry 4.0 lies the collection and analysis of data generated by equipment and production processes. This is made possible through the widespread deployment of sensors, communication systems, and control units—together forming the Industrial Internet of Things (IIoT). The value of this data is maximized when it is gathered in real time and directly from the production line. Thanks to ongoing technological progress, it is now feasible to monitor key parameters even in extreme conditions involving intense vibrations, chemical exposure, humidity, or radiation.
Yet, a major challenge remains unsolved: there is currently no battery capable of reliably powering IIoT devices at temperatures between 200 °C and 400 °C.
While this might appear to be a specialized concern, it has far-reaching implications. Globally, thousands of companies—worth billions of euros—operate in sectors such as iron and steel production, cement, chemicals, and petrochemicals, where processes frequently occur within this high-temperature range. These industries are actively seeking affordable and robust solutions for process monitoring, shifting from reactive and scheduled maintenance to preventive strategies. However, this shift is severely limited by a significant technological barrier: at elevated temperatures, conventional batteries suffer from material degradation, heat buildup, self-discharge, and the risk of thermal runaway. These issues make existing battery technologies unsuitable for high-temperature environments, effectively blocking the adoption of critical IIoT advancements.
The OxyBatt project directly addresses this gap by developing a secondary battery system capable of operating safely and reliably within the 200 °C to 400 °C range. The OxyBatt solution offers intrinsic safety and long-term stability, paving the way for reliable power storage in extreme industrial settings.
During the first reporting periods, efforts have been in taken in aligning the state of the technology to the identified industrial needs. Following a detailed product design and specification document, the consortium has identified the ideal battery architecture, which has been validated experimentally. Fully working prototypes have been fabricated and tested, demosntrating that the requested performance metrics are within reach. In parallel, activities for technology scale-up have been undertaken.
The min result so far is the decrease of the working temperature for the battery to 250 ºC, which was made possible by introducing an all-thin-film architecture. The key next needs are:
- Large area fabrication of the cell;
- Validation of industrial processing;
- Identification of new customers.
- Large area fabrication of the cell;
- Validation of industrial processing;
- Identification of new customers.