Configuring the Perfect System for Lithium-ion Battery Production

Lithium-ion Battery Cell Production

The production of lithium-ion batteries is a complex process that demands precision, efficiency, and adaptability. With the rapidly expanding global battery market, manufacturers face intense pressure to enhance performance and reduce costs.From transport and filling to mixing, dosing, and discharging, every stage of handling the battery powders must be planned to ensure a smooth, successful production run. This post will explore the key considerations when designing a material handling system tailored to address the intricacies of battery powders.

Powder Handling Challenges for Battery Manufacturers

Battery manufacturers face various challenges, particularly with the development of next-generation anode and cathode chemistries. These advancements promise significant battery capacity and life cycle improvements but may impose unforeseen requirements on the manufacturing process. Common challenges include:

• Achieving high containment levels and regulatory compliance
• Preventing cross-contamination
• Delivering adjustable flow rates for cohesive or extremely loose powders
• Preventing container corrosion when exposed to chemicals
• Blending without risk of contamination
• Ability to handle hot powders effectively

The Importance of Flexibility in Materials Handling Systems

When designing a materials handling system for lithium-ion battery production, flexibility is key. The system must handle various powder blends and adapt to production changes. Getting it right initially can mean the difference between efficient production and costly downtime.

Powder handling challenges might not appear during early lab-based chemistry development or even when scaling up to several hundred kilograms. The test begins with hundreds or thousands of kilograms in a single container, like a big bag or Intermediate Bulk Container (IBC). At this scale, it can be difficult to remove powders from the container without affecting their composition.

That's where Matcon's Cone Valve IBCs are beneficial. Our technology ensures a smooth, controlled discharge of powders, reducing the risk of segregation and material degradation. 

Improving Manufacturing Productivity and Efficiency

From transport and filling to mixing, dosing, and discharging hazardous, abrasive, and poor-flowing powders, Matcon's Modular System for Battery Material Manufacturing supports the lithium-ion battery production process.

Key Features of Matcon's System

• Containment: No moisture ingress, with high-value materials safely contained in IBCs until discharged.
• Transporting Materials: Safe powder handling throughout production steps, from filling to discharge points in IBCs.
• Discharging Powders: Even, accurate dosing via mass flow, with reliable and complete material discharge.
• Quality at All Stages: Lean manufacturing system modules with no open processing, reducing contamination risks.

Materials Handled by Matcon Equipment

Matcon's durable equipment processes a range of materials, including:

• Lithium Hydroxide Monohydrate (LiOH.H2O)
• Lithium Nickel Manganese Cobalt Oxides (LiNiMnCo, NMC, NCM)
• Nickel Hydride (NiMH or Ni–MH) 
• Sodium Carboxymethyl Cellulose (CMC)
• Lithium Thionyl Chloride (Li-SOCl2) 
• Magnesium Chloride (Mg-ion)
• Cobalt
• Nickel Nitrate Ni–Zn)
• Calcium Chloride
• Kynar PTFE – Fluoroplastic Resin
• Polyvinyl Pyrrolidone (PVD, PVDF)

Working with manufacturers of lithium-ion batteries

Leading battery manufacturers worldwide have chosen Matcon IBC systems for their production processes for several reasons:

• Tried-and-tested technology with decades of experience
• Fully automated powder handling solutions for increased productivity and efficiency
• Safe transfer of hazardous powders without the risk of operator exposure
• Customisable IBC systems to suit exact powder handling requirements
• Efficient dry blending for battery powders with high-shear capability

Comprehensive Support from Consultation to Installation

From the initial consultation to design and installation, Matcon works closely with clients to ensure their IBC systems meet specific needs. Additionally, we offer ongoing training, preventative maintenance, and exceptional aftersales support to ensure your system continues to operate at peak efficiency.

Select the Correct Equipment from Day One

Choosing the right powder handling solution and system setup from the start is crucial. Matcon provides expertise to tackle the most challenging battery manufacturing operations. By ensuring the smooth and efficient handling of battery powders, Matcon's systems help manufacturers achieve their production goals while maintaining the highest standards of quality and safety.