Spray-Drying of Electrode Materials for Lithium- and Sodium-Ion Batteries

Abstract

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.

Opportunities for the State-of-the-Art Production of LIB Electrodes—A Review

“…Hawley et al [55] reviewed the challenges that come with the standard wet-electrode processing, with particular focus on optimising wet slurry properties, the expensive recovery of NMP solvent, and the microstructural defects during solvent drying processes. Like Hawley et al [55], Wenzel et al [56] and Verteuyen et al [57] also discussed the state-of-the-art mixing and coating techniques. The effect of a high coating thickness [58] and electrode porosity [59] on electrochemical performance has also been reviewed.…”

Interplay of Porosity, Wettability, and Redox Activity as Determining Factors for Lithium–Organic Electrochemical Energy Storage Using Biomolecules

“…In studies on organic electrode materials, conductive additives such as carbon materials are often considered passive parts of the electrode composition . To describe charge storage in organic materials more thoroughly, sometimes electrodes without organic active materials are designed, and the resulting capacity is subsequently subtracted from the total capacity.…”

“…[20] In studies on organic electrode materials, conductive additives such as carbon materials are often consideredp assive parts of the electrode composition. [21,22] To describe charge storagei no rganic materials more thoroughly,s ometimes electrodes without organic active materials are designed, and the resultingc apacity is subsequently subtracted from the total capacity.H owever,s uch investigations suffer from the possible systematic error when neglecting the modificationo fc harge storagep roperties of carbona dditives by organic active materials.…”

Recent Advances in Aerosol‐Assisted Spray Processes for the Design and Fabrication of Nanostructured Metal Chalcogenides for Sodium‐Ion Batteries

“…In this regard,a erosol-assisted processes, in particulars pray pyrolysis and spray drying, have gained recent prominence owing to their feasibility,s calability, cost-efficiency,a nd minimal waste production. [43][44][45][46][47][48][49][50][51][52][53][54][55][56] Above all, these processes usually result in various nanostructured compositeso fn anocrystalline host materials with carbon frameworks that can effectively benefit electrochemical performance. [47][48][49]57] Herein, we presentr ecent advances in the syntheses of nanostructured metal chalcogenides by spray pyrolysis and spray drying for use as SIB anode materials.…”

“…Therefore, process optimization is vital for the preparation of anode materials for high‐performance SIBs. In this regard, aerosol‐assisted processes, in particular spray pyrolysis and spray drying, have gained recent prominence owing to their feasibility, scalability, cost‐efficiency, and minimal waste production . Above all, these processes usually result in various nanostructured composites of nanocrystalline host materials with carbon frameworks that can effectively benefit electrochemical performance …”