Periodic Reporting for period 3 - LISA (Lithium sulphur for SAfe road electrification)
Periodo di rendicontazione: 2022-02-01 al 2022-12-31
LiS is a promising alternative to Li-ion battery technology as it is free of critical raw material (CRM) and non-limited in capacity and energy by material of intercalation. LISA proposed the development of high energy and safe LiS battery cells with hybrid solid state non-flammable electrolytes validated at cell level according to automotive standard.
LISA has been addressing specific LiS bottlenecks on metallic lithium protection, power rate, and volumetric energy density; together with cost as the main selection criteria for EV batteries. The sustainability of the technology has been assessed from an environmental and economic perspective. The LISA technology is delivered ready for use with state of charge and state of health estimators developed to facilitate battery pack integration. LISA reached a relevant impact on existing and next-generation EV batteries, delivering technology about 410Wh/kg for 18Ah pouch cell, still cycling after 400 cycles and 50% BoL, free of Cobalt and Nickel..
The principal LISA achievement are:
•. Hazar level demonstrated for LiS lower than 4
• To reduce the lithium excess with lithium infiltration process developed at pilot scale
• To deliver Li-S cells prototype reaching: 18 Ah, 410 Wh kg-1, 450 Wh L-1, , >4.000 cycles maintaining 80% DoD and 50% of BoL at cell level
• 1 State-of-Charge and 2 State of health ageing estimators have been developed to supporte the future development of Battery Management System for EV pack integration and 2nd life use assessment.
• > 90 wt%. recyclability of Lithium from 20Ah pouch cell has been demonstrated at lab-scale.
LISA has been addressing specific LiS bottlenecks on metallic lithium protection, power rate, and volumetric energy density; together with cost as the main selection criteria for EV batteries. The sustainability of the technology has been assessed from an environmental and economic perspective. The LISA technology is delivered ready for use with state of charge and state of health estimators developed to facilitate battery pack integration. LISA reached a relevant impact on existing and next-generation EV batteries, delivering technology about 410Wh/kg for 18Ah pouch cell, still cycling after 400 cycles and 50% BoL, free of Cobalt and Nickel..
The principal LISA achievement are:
•. Hazar level demonstrated for LiS lower than 4
• To reduce the lithium excess with lithium infiltration process developed at pilot scale
• To deliver Li-S cells prototype reaching: 18 Ah, 410 Wh kg-1, 450 Wh L-1, , >4.000 cycles maintaining 80% DoD and 50% of BoL at cell level
• 1 State-of-Charge and 2 State of health ageing estimators have been developed to supporte the future development of Battery Management System for EV pack integration and 2nd life use assessment.
• > 90 wt%. recyclability of Lithium from 20Ah pouch cell has been demonstrated at lab-scale.
In WP2 (Specification), Cell and Test Definition and Production Processes Definition reports have been produced. Specific interlaboratory Round Robin tests have been run between the laboratories and allowed to consolidate a reference set up based on liquid electrolyte.
In WP3 (Lithium anode and solid-state electrolyte), Lithium and ceramic solid-state electrolytes were developed and tested. Production of well-performing lithium layers on Cu by pulsed lased deposition (PLD) was demonstrated. LGPS sulfide solid electrolyte was also successfully deposited by PLD on nanocellulose based membrane separator which was done by electrospinning and showed improved thermomechanical properties when compared to commercial polyolefin. Besides, CNF-based carbon scaffolds have been prepared and supplied to partner working on Lithium infiltration to produce lighter anode and to reduce the lithium excess. Upscaling of the PLD process for lithium layers was started and demonstrated, but the developed processes didn’t reach sufficient maturity to be upscaled. However, it has been clarified the dependence of the Li anode with the cycling shortening the lifetime of the battery, not related to the S cathode.
WP4 (Stand-alone dielectric) focused on the fabrication of a stand-alone dielectric layer to be incorporated as the solid electrolyte in the final cell. The major challenge of finding a stable polymeric matrix which hosts a ceramic material compatible with lithium was solved, and the coating of HSE on commercial separator by comma bar was achieved in the framework of LISA. The upscaled component was evaluated in pouch cell and cylindrical cell (in this case without the ceramic (only polymeric coating)) with promising results.
In WP5 (S/C cathode), partners have further adapted the co-extrusion composites. Results show a gravimetric energy density of 410 Wh/kg and 450 Wh/L for the liquid system in a 18Ah pouch cell and approximately 213 Wh/kg for the hybrid system. Cycle life ranges from 1200 cycles at 50% DoD for the liquid system to more than 175 cycles for the hybrid system. IWS demonstrated the solvent-free fabrication of a 2nd generation cathode, using their proprietary DRYtraec© process which was also demonstrated for all-solid-state batteries. LISA provided at least 3 different manufacturing options for S/C cathodes at pilot level (TRL5) enabling the production of > 210Wh/kg multi-layered pouch cells. Further investigation is mandatory to enhance the HSE-cathode interphase, particularly at pouch cell level.
WP6 (Modelling, cell prototyping and validation) covered three distinct activity groups: the application of theoretical techniques to support design and operational improvements; carbon synthesis and cell manufacture; and electrochemical and safety testing. Partners used pre-existing LiS cells to develop new methods for state of charge/state of health determination, which can be applied future cells such as those from the LISA project as they become available. In the second activity group, partners performed haracterization on a selection of carbons, leading to a demonstration of how varying porosity alters the cycling characteristics of cells. LISA also provided methods for state of charge estimation using using machine learning and methods for state of health estimation. Besides, testing of the new HSE produced by LISA in WP4 was successfully tested in pouch cell having surpassed the 240 cycles at 100% DOD with a relative retainment of 60% of capacity while emulating a normal degradation curve.
WP7 focused on the principles of the circular economy. LISA is demonstrating up to 92% wt of lithium recovery from LiS Black Mass through water based and CO2 consuming processes and, for the liquid system, the global recycling efficiency reaches up to 51.8% (considering recycling as converting waste into reusable material) or up to 49.4% (considering 30% loss during sulphur refining).
WP8 covered the communication, dissemination, and exploitation of the project results. The result of this WP is the creation of dissemination and communication materials and the launch of communication channels. Technology and IPR monitoring reports for the project were prepared while exploitation and business planning activities have focused on the development of a preliminary business model for the LISA project.
In WP3 (Lithium anode and solid-state electrolyte), Lithium and ceramic solid-state electrolytes were developed and tested. Production of well-performing lithium layers on Cu by pulsed lased deposition (PLD) was demonstrated. LGPS sulfide solid electrolyte was also successfully deposited by PLD on nanocellulose based membrane separator which was done by electrospinning and showed improved thermomechanical properties when compared to commercial polyolefin. Besides, CNF-based carbon scaffolds have been prepared and supplied to partner working on Lithium infiltration to produce lighter anode and to reduce the lithium excess. Upscaling of the PLD process for lithium layers was started and demonstrated, but the developed processes didn’t reach sufficient maturity to be upscaled. However, it has been clarified the dependence of the Li anode with the cycling shortening the lifetime of the battery, not related to the S cathode.
WP4 (Stand-alone dielectric) focused on the fabrication of a stand-alone dielectric layer to be incorporated as the solid electrolyte in the final cell. The major challenge of finding a stable polymeric matrix which hosts a ceramic material compatible with lithium was solved, and the coating of HSE on commercial separator by comma bar was achieved in the framework of LISA. The upscaled component was evaluated in pouch cell and cylindrical cell (in this case without the ceramic (only polymeric coating)) with promising results.
In WP5 (S/C cathode), partners have further adapted the co-extrusion composites. Results show a gravimetric energy density of 410 Wh/kg and 450 Wh/L for the liquid system in a 18Ah pouch cell and approximately 213 Wh/kg for the hybrid system. Cycle life ranges from 1200 cycles at 50% DoD for the liquid system to more than 175 cycles for the hybrid system. IWS demonstrated the solvent-free fabrication of a 2nd generation cathode, using their proprietary DRYtraec© process which was also demonstrated for all-solid-state batteries. LISA provided at least 3 different manufacturing options for S/C cathodes at pilot level (TRL5) enabling the production of > 210Wh/kg multi-layered pouch cells. Further investigation is mandatory to enhance the HSE-cathode interphase, particularly at pouch cell level.
WP6 (Modelling, cell prototyping and validation) covered three distinct activity groups: the application of theoretical techniques to support design and operational improvements; carbon synthesis and cell manufacture; and electrochemical and safety testing. Partners used pre-existing LiS cells to develop new methods for state of charge/state of health determination, which can be applied future cells such as those from the LISA project as they become available. In the second activity group, partners performed haracterization on a selection of carbons, leading to a demonstration of how varying porosity alters the cycling characteristics of cells. LISA also provided methods for state of charge estimation using using machine learning and methods for state of health estimation. Besides, testing of the new HSE produced by LISA in WP4 was successfully tested in pouch cell having surpassed the 240 cycles at 100% DOD with a relative retainment of 60% of capacity while emulating a normal degradation curve.
WP7 focused on the principles of the circular economy. LISA is demonstrating up to 92% wt of lithium recovery from LiS Black Mass through water based and CO2 consuming processes and, for the liquid system, the global recycling efficiency reaches up to 51.8% (considering recycling as converting waste into reusable material) or up to 49.4% (considering 30% loss during sulphur refining).
WP8 covered the communication, dissemination, and exploitation of the project results. The result of this WP is the creation of dissemination and communication materials and the launch of communication channels. Technology and IPR monitoring reports for the project were prepared while exploitation and business planning activities have focused on the development of a preliminary business model for the LISA project.
The production of a working Li-S battery cell for these applications requires improvement over all cell components including:
1. Two lithium anode manufacturing processes have been successfully demonstrated at pilot and lab level to minimise the dead mass and increasing the volumetric energy and/or the gravimetric energy: depositing Li on Cu by physical PLD process and Li on lithophilic carbon through lithium melting and infiltration process.
2. Hybrid solid state electrolyte on ceramic embedded in polymer matrix has been developed and tested. The hybrid polymeric system has been up-scaled (more than 300m) by coma bar.
3. Four types of S/C cathodes manufacturing processes have been developed in the framework of LISA, including low and high density cathodes, based either ink coating or dry manufacturing. At least three S/C cathode type have been developed in the framework of LISA at pilot level.
4. 18Ah pouch cell of 410Wh/kg and 450Wh/L has been demonstrated in the framework of LISA. Other 6Ah pouch cell have reached > 1.200 cycles of the 80% BoL and 50% DoD.
1. Two lithium anode manufacturing processes have been successfully demonstrated at pilot and lab level to minimise the dead mass and increasing the volumetric energy and/or the gravimetric energy: depositing Li on Cu by physical PLD process and Li on lithophilic carbon through lithium melting and infiltration process.
2. Hybrid solid state electrolyte on ceramic embedded in polymer matrix has been developed and tested. The hybrid polymeric system has been up-scaled (more than 300m) by coma bar.
3. Four types of S/C cathodes manufacturing processes have been developed in the framework of LISA, including low and high density cathodes, based either ink coating or dry manufacturing. At least three S/C cathode type have been developed in the framework of LISA at pilot level.
4. 18Ah pouch cell of 410Wh/kg and 450Wh/L has been demonstrated in the framework of LISA. Other 6Ah pouch cell have reached > 1.200 cycles of the 80% BoL and 50% DoD.