Scale-up of a novel melt-synthesis process for the manufacturing of C-LiFePO4 for automotive applications

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Liquid phase synthesis of LiFeP04 has already been demonstrated in laboratory-scale trials and was identified as apossible low-cost alternative for manufacturing pathway. The high temperautre process in the liquid phase, benefitsfrom rapid reaction kinetics and the thermodynamic stability of LiFeP04 in a reducing atmosphere. The aim of thepresent proposed work is to develop and pilot of the molten synthesis process and accelerate its scale-up to acommercial-scale for the manufacturing of low-cost C-LiFeP04 for EV and PHEV applications.Main project steps are:1. Reactant selection and formulation2. Degassing, mixing, melting and casting3. Ingot comminution to'sub-micron size4. Spray drying (if needed, following wet milling)5. Pyrolysis and carbon coating (optionally in a gas-solid contactor)6. Laboratory testing in small cells7. Field testing by customers EV and PHEV applications8. Techno-economic evaluation of industrial-scale plantSteps 2 and 3 are seen as the most critical to achieve the project goals of cost and stable performance on cycling.Step 5 is also an important step. II is believed that carbon deposition in a gas-solid c6ntactor (e.g. fluidized bed) willimprove the performance (e.g. cycle-life, conductivity) of the C-LiFeP04 over Phostech's existing carbon coatingapproach.