korea advanced battery conference 2021
TRANSCRIPT
Thermal Solutions for the Production of Battery Materials
Korea Advanced Battery Conference 2021
October 14, 2021
www.onejoon.com
© ONEJOON | 2020
Agenda
01
02 Thermal Solutions
How to make a difference
03 Thermal Solutions
for Battery Materials
ONEJOON at a glance
Corporate History
125-year track records of customized high-temperature industrial furnaces
3 / 23
Global Location
USA (Minneapolis, Atlanta)Poland (Gliwice)
Germany (Bovenden, Boeblingen)
Korea (Suwon, Hwaseong)
Operations in nine(9) sites, five(5) countries
China (Shanghai, Haining Zhejiang)
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Thermal Solutions for Advanced Materials
Providing comprehensive experience for thermal processes up to 3000°C
5 / 23
Thermal Solutions with Kilns & Furnaces
Kilns (Furnaces) for continuous operation
Tunnel Kiln
Roller Hearth Kiln
Pusher Kiln
Mesh-belt Kiln
Rotary Kiln
Customized Kiln
Atmospheres
Inert Atmosphere
Active Atmosphere
Flammable Atmosphere
Vacuum
Muffle Furnace Oxidation Oven Rotary Kiln Pusher Kiln Tunnel Kiln
Kilns (Furnaces) for batch operation
Shuttle Kiln
Lift-Bottom Kiln
Vacuum-Muffle Kiln
Top Hat Kiln
Chamber Kiln
Customized kiln
Batch Kiln Vacuum Furnace Lift Bottom Kiln High Temperature circulation Kiln Vertical Tube Furnace
Processes
Drying
Pyrolysis
Carbonization
Activation
Passivation
Deposition / Infiltration
Graphitization
Customized services for various industries
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Thermal Solutions by Process Engineering
Process Equipment
Powder Materials Handling
(Mixer, Hopper, Filter, …)
Pneumatic Conveying System
Quenching
Surface Treatment
Heat Recovery
Exhaust Gas Purification Systems
Turnkey Solutions
Process Development
Pre-engineering
System Integration
EPC-contracting
Complete Thermal Processing Lines
Material Flow Systems
Storage/Buffer Solutions
Gantry robots
Loading and unloading
equipment
Working-stations
Conveyor technic
Powder Handling
Carbon Fiber Processing LineBattery Material Processing Line
Optimization by process integration
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Thermal Solutions from Lab to Mass Production
Service Portfolio
Testing facilities and deep expertise in thermal processes
Broad range of testing facilities including electrically heated and gas fired ovens and furnaces,
with different types of atmosphere
Testing of diverse process conditions and plant designs
Define the right process parameters to scale up production
High flexibility in order to define the right process parameters under production conditions
Highly cost effective and efficient volume production as a result
Diversified expert team to provide consultancy and trouble shooting
Analysis of existing processes at customers’ production facilities
CFD simulation to better understand the impact of furnace design on process conditions
Joined development with national and international partners
Benefit
Benefit from expert knowledge
Develop and optimise thermal processes and production processes
Perform tests under realistic and ideal testing conditions
Early stage risk identification and development of alternative solutions
Transfer processes to industrial-scale production
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Agenda
01
02 Thermal Solutions
How to make a difference
03 Thermal Solutions
for Battery Materials
ONEJOON at a glance
Capacity Challenge
What is the best type of kiln?
More kilns or Larger kiln?
Need a customized design for a specific application?
Kiln determines product capacity as well as quality and productivity
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Cathode Active Material Challenges
Calcination on mass scale is difficult to control
Complexity increases with Ni content of CAM
High sensitivity of high-Ni CAM on:
• Temperature homogeneity
• Homogenous gas(Oxygen) distribution
• Lithium gradient
Mass production leads to poor performance
Air
O2H2O, CO2
H2O, CO2
Low Ni CAM High Ni CAM
Quality deviations due to kiln structure
• Heater location (radiation, conduction, convection)
• Injected gas flow and temperature
• Exhaust gas flow and location
• Transport medium (rollers, carts, plates, etc)
• Insulation materials and plan
• Dimension (length, height, width)
• Environment
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Anode Material Challenges
Closed type continuous graphitization process is more efficient than open type Acheson processIn terms of environmental issues and energy consumption
Source : Saint Gobain, Acheson Process
Artificial Graphite
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Conventional Batch Process New Continuous Process
Natural graphite
Polymer based
Deposition based
Bio material based
Petrocoke based
Artificial Carbon
& Silicon Composites
Anode
Materials
Silicon based
New anode materials require new thermal process and solutions
Anode Material ChallengesCarbon & Silicon Composites
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Scale-Up Procedure
Challenges
Material Properties
ProcessControl
Plant Efficiency
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Target for a Sustainable Production
Reduction of the energy consumption and emission
Temperature and atmosphere control to improve the yield
Minimizing manual operation by integration of the system
Improving material properties and quality
Increasing throughputs
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Agenda
01
02 Thermal Solutions
How to make a difference
03 Thermal Solutions
for Battery Materials
ONEJOON at a glance
Production Process of Cathode Active Materials
Optimal integration of the process and thermal solutions is a competitive advantageThermal solutions determine process competitiveness
→ kiln type & specification, dimensions, cost, utility consumption, product throughputs & quality, etc.
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Raw MaterialsMixing
PrimaryCalcination
MillingAir Classifying
ScreeningFiltering
SecondaryCalcination
AdditivesMixing
Blending
Packing
Roller Hearth Kiln, a State-of-the-Art thermal process of CAM
Roller Hearth Kiln is most widely used for CAM calcination.
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GAS GAS GAS GAS GAS
Lithium Hydroxide
p-CAM Heating (Chemical & Physical Reactions, Grains Growth) Cooling
Key Features of RHK
• Excellent temperature uniformity @ 800~1000℃
• Controllable gas flows
• First in, First out (products)
• Limitation of a loading weight (rollers)
• Heat loss through rollers
• Operation & Maintenance experts required
Kilns for Cathode Active Materials
Roller Hearth Kiln
Pusher Kiln
Rotary Kiln
Pusher Kiln and Rotary Kiln are developed as the alternative solutions of the main calcination as well as pre-calcination, drying and coating.
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Kilns Comparison for Cathode Active Matrials
Choosing a right kiln is the first step of the optimal process design
RK RHK PK
Gas tightness weak good very good
Contamination issues Bad negligible negligible
Energy efficiency very high medium high
Maximum annual capacity very high low high
cycling speedat low capacity very high high high
at high capacity very high high medium
Temperature homogeneityat low capacity very high high high
at high capacity very high low high
Gas flow controlat low capacity low medium high
at high capacity low low highQuality index considering temperature homogeneity, gas flow control, contaminations, etc.
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Alternative Thermal Solutions
New type of kilns are under the development to increase the production capacity
※ Series of experiments have been done for validation of concept to optimize and validate the CFD simulation model
CFD Simulation Batch Test Module Continuous Type Kiln
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Alternative Thermal Solutions
New development PK, upgraded from CAM RHK, will achieve larger throughputs
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Furnace or Reactor for Anode Materials
Typical Process
Drying
Vapor release
Pyrolysis
Carbonization
Activation
Passivation
Deposition
Graphitization
……
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Thermal Solutions for Every Challenge
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