Periodic Reporting for period 3 - Hydra (Hybrid power-energy electrodes for next generation lithium-ion batteries)
Reporting period: 2023-05-01 to 2024-08-31
Electric mobility has become an important foundation for the future of European industry and society. Electric vehicles require high-performance batteries that can store a large amount of energy and be charged quickly. Furthermore, these batteries must use sustainably sourced materials, avoid supply chain bottlenecks and price fluctuations. The battery landscape is quickly shifting to meet these challenges, but some fundamental obstacles remain.
The aim of HYDRA was to develop the next generation of commercially viable Li-ion battery cells based on sustainable materials and manufacturing processes. Within the roadmap for future battery development, these Li-ion battery cells are referred to as generation 3b. They aim to increase the energy density of the cells by developing new materials, while also reducing the critical raw materials (CRM) content by more than 20%. To achieve this goal, high-capacity silicon is blended together with synthetic graphite in the anode and cobalt-free lithium nickel manganese oxide (LNMO) is used in the cathode. In addition, aqueous processing of cathodes has been developed, circumventing the need for use of organic solvents in the manufacturing process for battery cells. Also, to reduce the flammability of the batteries, ionic liquid electrolytes are introduced into the cells.
HYDRA brings together leading industry and research partners to identify novel solutions to extend the cycle life of these cells and support the growing European battery industry. At the end of the project, the HYDRA project has demonstrated HYDRA.2 cells with silicon graphite anodes produced by Vianode, LNMO cathodes from Topsoe and ionic liquid electrolytes from Solvionic, establishing Vianode and Solvionic as significant contributors to the European value chain for battery production. Through the development of sustainable and high-performance Li-ion cells, HYDRA contributed to the future of electric mobility and help support the Green Transition.
Throughout the work in the project, it is very important to engage with both the European battery community and the public. HYDRA has worked to support the community by making as much data as possible available using the FAIR data standards. Furthermore, the modelling tools developed in the project were made open-source. HYDRA also interacted directly with researchers from around Europe via the Access HYDRA program, in which researchers, engineers, or students could apply for short research stays at HYDRA partner institutes to develop skills or knowledge related to the project objectives.
The aim of HYDRA was to develop the next generation of commercially viable Li-ion battery cells based on sustainable materials and manufacturing processes. Within the roadmap for future battery development, these Li-ion battery cells are referred to as generation 3b. They aim to increase the energy density of the cells by developing new materials, while also reducing the critical raw materials (CRM) content by more than 20%. To achieve this goal, high-capacity silicon is blended together with synthetic graphite in the anode and cobalt-free lithium nickel manganese oxide (LNMO) is used in the cathode. In addition, aqueous processing of cathodes has been developed, circumventing the need for use of organic solvents in the manufacturing process for battery cells. Also, to reduce the flammability of the batteries, ionic liquid electrolytes are introduced into the cells.
HYDRA brings together leading industry and research partners to identify novel solutions to extend the cycle life of these cells and support the growing European battery industry. At the end of the project, the HYDRA project has demonstrated HYDRA.2 cells with silicon graphite anodes produced by Vianode, LNMO cathodes from Topsoe and ionic liquid electrolytes from Solvionic, establishing Vianode and Solvionic as significant contributors to the European value chain for battery production. Through the development of sustainable and high-performance Li-ion cells, HYDRA contributed to the future of electric mobility and help support the Green Transition.
Throughout the work in the project, it is very important to engage with both the European battery community and the public. HYDRA has worked to support the community by making as much data as possible available using the FAIR data standards. Furthermore, the modelling tools developed in the project were made open-source. HYDRA also interacted directly with researchers from around Europe via the Access HYDRA program, in which researchers, engineers, or students could apply for short research stays at HYDRA partner institutes to develop skills or knowledge related to the project objectives.
During the last reporting period of the project, a set of HYDRA.2 cells were produced at ICSI and CEA, and tested at DLR. The cells utilized the Si/Gr anode material that was produced by ELKEM in collaboration with Vianode, LNMO cathode material produced by Topsoe and both ionic liquid and carbonate electrolyte materials produced by Solvionic. The best cells produced were close to reaching the technical KPIs set in the LC-BAT5 call.
The project has performed a thorough sustainability analysis, with a global value chain analysis, and economic value chain analysis in addition to a life cycle assessment on the local scale. These assessments showed that the HYDRA cells performed well within the KPIs defined on cost and CRMs.
The results have been disseminated both in scientific publications and through outreach to the general public, through channels like LinkedIn, podcasts and YouTube videos. Results from the project have been presented in more than 40 presentations all over Europe, and almost 20 written publications have been submitted.
The project has performed a thorough sustainability analysis, with a global value chain analysis, and economic value chain analysis in addition to a life cycle assessment on the local scale. These assessments showed that the HYDRA cells performed well within the KPIs defined on cost and CRMs.
The results have been disseminated both in scientific publications and through outreach to the general public, through channels like LinkedIn, podcasts and YouTube videos. Results from the project have been presented in more than 40 presentations all over Europe, and almost 20 written publications have been submitted.
HYDRA aimed to advance beyond the state of the art in at least 5 areas: cathode materials, anode materials, electrolytes, digitalization, and sustainable scale-up.
The development of cathode materials in HYDRA seeks to circumvent the problems that have so-far limited the performance of high-voltage spinel materials like LNMO. By developing blended cathodes, applying surface treatments, synthesizing doped LNMO, and optimizing particle size, HYDRA's approach seeks to reduce cation dissolution, enhance cell power, and minimize electrolyte degradation. Additionally, the adopted processes are more environmentally friendly, achieving performance targets without the use of cobalt as a critical raw material. Strong focus on the scalability of the approach will maximize the chances of industrial realization.
Anode material development in HYDRA will seek to maximize the capacity of the electrode by blending significant amounts of European produced Si with graphite. HYDRA will develop composites with low area/volume ratio and high cycling stability. In an optimized binder-conductive additive-system, these composites will give high energy density with the required cycling stability necessary for industrial relevance. The use of synthetic graphite reduces the reliance on mining natural graphite, which is a CRM.
The development of electrolytes seeks to support the unique processes at both electrodes while also being very stable and highly ionically conductive. HYDRA has developed a new generation of electrolytes stable at the high working voltages of our proposed cathode materials and stable with the anode. Using surface characterization techniques, HYDRA’s investigate on the Si-graphite anode surface passivation to avoid continuous electrolyte degradation by controlling the SEI formation at the Si surface. As giga-scale production of batteries is growing across Europe, the use of sustainable manufacturing processes is more important than ever.
HYDRA has developed solutions for all-aqueous based electrodes for Li-ion HYBRID batteries and demonstrate them in pilot scale. The water-based chemistries will reduce the need for dry-rooms, decreasing manufacturing energy consumption. This will provide the environmentally friendly and economically sustainable production processes necessary to obtain the high energy, generation 3b Li-ion batteries necessary for a decarbonized Europe.
Taken together, these individual improvements on the state of the art paves the way for a new generation of Li-ion battery cells with not only beyond state-of-the-art performance KPIs for energy density and cycle life, but also sustainably based manufacturing processes and model-accelerated development workflows. This is essential to establishing a successful and environmentally friendly battery industry in Europe. In pursuit of this goal, HYDRA has also educated the up-and-coming generation of scientists and engineers by supporting students, post-docs, and early career researchers in the project. As the demand for batteries increases around the world, HYDRA has contributed to the European society to benefit from the Green Transition in terms of education, jobs, access to clean energy, and improved environmental quality.
The development of cathode materials in HYDRA seeks to circumvent the problems that have so-far limited the performance of high-voltage spinel materials like LNMO. By developing blended cathodes, applying surface treatments, synthesizing doped LNMO, and optimizing particle size, HYDRA's approach seeks to reduce cation dissolution, enhance cell power, and minimize electrolyte degradation. Additionally, the adopted processes are more environmentally friendly, achieving performance targets without the use of cobalt as a critical raw material. Strong focus on the scalability of the approach will maximize the chances of industrial realization.
Anode material development in HYDRA will seek to maximize the capacity of the electrode by blending significant amounts of European produced Si with graphite. HYDRA will develop composites with low area/volume ratio and high cycling stability. In an optimized binder-conductive additive-system, these composites will give high energy density with the required cycling stability necessary for industrial relevance. The use of synthetic graphite reduces the reliance on mining natural graphite, which is a CRM.
The development of electrolytes seeks to support the unique processes at both electrodes while also being very stable and highly ionically conductive. HYDRA has developed a new generation of electrolytes stable at the high working voltages of our proposed cathode materials and stable with the anode. Using surface characterization techniques, HYDRA’s investigate on the Si-graphite anode surface passivation to avoid continuous electrolyte degradation by controlling the SEI formation at the Si surface. As giga-scale production of batteries is growing across Europe, the use of sustainable manufacturing processes is more important than ever.
HYDRA has developed solutions for all-aqueous based electrodes for Li-ion HYBRID batteries and demonstrate them in pilot scale. The water-based chemistries will reduce the need for dry-rooms, decreasing manufacturing energy consumption. This will provide the environmentally friendly and economically sustainable production processes necessary to obtain the high energy, generation 3b Li-ion batteries necessary for a decarbonized Europe.
Taken together, these individual improvements on the state of the art paves the way for a new generation of Li-ion battery cells with not only beyond state-of-the-art performance KPIs for energy density and cycle life, but also sustainably based manufacturing processes and model-accelerated development workflows. This is essential to establishing a successful and environmentally friendly battery industry in Europe. In pursuit of this goal, HYDRA has also educated the up-and-coming generation of scientists and engineers by supporting students, post-docs, and early career researchers in the project. As the demand for batteries increases around the world, HYDRA has contributed to the European society to benefit from the Green Transition in terms of education, jobs, access to clean energy, and improved environmental quality.