The performance of electrode materials in lithium-ion (Li-ion), sodium-ion (Na-ion) and related batteries depends not only on their chemical composition but also on their microstructure. The choice of a synthesis method is therefore of paramount importance. Amongst the wide variety of synthesis or shaping routes reported for an ever-increasing panel of compositions, spray-drying stands out as a versatile tool offering demonstrated potential for up-scaling to industrial quantities. In this review, we provide an overview of the rapidly increasing literature including both spray-drying of solutions and spray-drying of suspensions. We focus, in particular, on the chemical aspects of the formulation of the solution/suspension to be spray-dried. We also consider the post-processing of the spray-dried precursors and the resulting morphologies of granules. The review references more than 300 publications in tables where entries are listed based on final compound composition, starting materials, sources of carbon etc.

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The growing interest in Na-ion batteries as a “beyond lithium” technologies for energy storage drives the research for high-performance and environment-friendly materials. Na2Ti3O7 (NTO) as an eco-friendly, low-cost anode material shows a very low working potential of 0.3 V vs Na+/Na but suffers from poor cycling stability, which properties can be significantly influenced by materials synthesis and treatment. Thus, in this work, the influence of the calcination time on the electrochemical performance and the reaction mechanism during cycling were investigated. NTO heat-treated for 48 h at 800 °C (NTO-48h) demonstrated enhanced cycling performance in comparison to NTO heat-treated for only 8 h (NTO-8h). The pristine material was thoroughully characterized by X-ray diffraction, laser granulometry, X-ray photoelectron spectroscopy, and specific surface area measurements. The reaction mechanisms induced by sodiation/desodiation and cycling were investigated by opernado XRD. Electrochemical impedance spectroscopy was used to evidence the evolution of the solid electrolyte interface layer (SEI) and modification of charge transfer resistances as well as the influence of cycling on capacity decay. The evolution of the crystallographic structure of NTO-48h revealed a more ordered structure and lower surface contamination compared to NTO-8h. Moreover, the residual Na4Ti3O7 phase detected after the sodium extraction step in NTO-8h seems correlated to the lower electrochemical performance of NTO-8h compared to NTO-48h.