Silicon-based batteries have emerged as the breakthrough in energy storage as the industry quickly reacts to various policy changes and demand fluctuations. Silicon-based batteries are quickly supplanting lithium-ion-based batteries as the preferred choice in industries that require long-duration energy storage, as silicon batteries have proven to have a significantly higher (up to 10x) energy density. The commercial viability of silicon-based batteries hinges on overcoming key challenges, including but not limited to particle size, purity, and uniformity. Elcan Industries has been working closely with companies to advance this process using advanced sieving and classification techniques.
Why Particle Size Matters:
Controlling and maintaining a consistent particle size is critical in developing silicon-based batteries. Consistent particle size allows for uniformity of the silicon being put into the battery, which allows for predictable battery performance. The ability to sieve finer allows manufacturers to use finer particles with a higher surface area. To do this, a strict particle size distribution must be met to avoid unwanted reactions. Furthermore, proper classification of silicon particles is required to minimize swelling-induced degradation.
Sieving silicon powders for battery materials typically requires separations from 1 micron up to 20 microns. There are many challenges associated with sieving silicon for battery materials that can be difficult to overcome using conventional and ultrasonic sieves and classifiers. Silicon powders are typically very sticky and tend to agglomerate. Screening machines that use a conventional vibratory energy spectrum cannot break up these agglomerations, which leads to a high amount of material not passing through the mesh that it should have. Furthermore, the industry requires high throughput rates at fine sizes below 20um, which are virtually impossible with standard equipment options.
The Role of Advanced Sieving
Elcan Industries offers state-of-the-art screening solutions that helps manufactures overcome these issues. The Hi-Sifter is the only high energy sieving machine employs a high energy approach for fine silicon powders without the use of ultrasonics or screen cleaning devices. This combined with the tensionless screen cloth allows for a smooth transfer of energy into the screening surface allowing for separations down to 10 microns. Furthermore, the high energy eliminates agglomerations issues by allowing for the fine particles to stratify on the surface of the screen and easily pash through the mesh. This allows for better dispersion of the particles when being used in slurries and enhances electrochemical performance.
Additionally, the Elbow Jet has successfully been used to make fine separations below 10um. The system is the only air classifier capable of simultaneously, multiple classifications allowing companies to achieve two cut points below 10 microns in a single pass without the use of a classifier wheel.
The ability to precisely control particle size allows companies to ensure tight distributions to meet exact formulation needs and separate out undesired oversized or ultrafine particles that could impact battery longevity. The result is increased yield with lower waste, high consistency of uniform particles and scalability which allows for materials to be processed at commercial scale and meet increases in demand as the industry advances.
In conclusion, as the use of silicon materials continues to increase due to the higher demand of long duration energy storage systems and electric vehicles, the ability to process the powder at fine sizes at a commercial scale becomes a critical process. Elcan Industries works with a variety of advanced equipment including the Hi-Sifter, Elbow-Jet Air Classifier, and CG Electromagnetic separator in order to make fine separations of the powder. All of the systems are available for testing and contract manufacturing at Elcan’s facility in Tuckahoe, NY.
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