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Researchers at Dalhousie University have developed a greener, less expensive and more sustainable process for manufacturing batteries that power electric vehicles -- an innovation that could greatly reduce the environmental impact of producing the vital components.

Most EV batteries store lithium in a lithium nickel manganese cobalt oxide (NMC) cathode, in which the nickel, manganese and cobalt elements are mixed in the crystal structure. Currently, NMC is made from a solution of metal salts dissolved in water. That process takes a lot of energy and water and produces waste, adding significantly to the carbon footprint of EV batteries.

Dr. Mark Obrovac, a professor in Dalhousie's departments of Chemistry and Physics and Atmospheric Science, wanted to see if there were more environmentally friendly and sustainable ways to make the same high-quality materials used in lithium-ion (Li-ion) batteries.

In 2019, his lab discovered a way to make cathode materials for Li-ion batteries using no water. In the new process, metal oxide powders are mixed and then heated, avoiding the use of water completely. This work was funded by an NSERC Alliance Grant with NOVONIX Battery Technology Solutions as the industrial partner. NOVONIX has since developed this work into the all-dry, zero-waste cathode synthesis process at the pilot-scale in their Dartmouth facility. That process was confirmed last year to be much more efficient, more economical and more sustainable than conventional methods, and it was recently awarded patent protection.

Dr. Obrovac's lab has now used all-dry methods to make materials that have not been previously possible, significantly improving materials' performance. His lab recently reported the all-dry synthesis of a new form of another popular cathode material for EV batteries called LiFePO₄, having a 28 per cent increase in energy storage compared to conventional materials.

Dr. Obrovac is available to discuss this important work and how it will lead to higher performing Li-ion batteries at a lower cost and improved sustainability.

Work on the all-dry process is outlined in the following published papers:

Cell Reports Physical Science
Journal of the Electrochemical Society
Chemistry of Materials

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Media contact:

Alison Auld
Senior Research Reporter
Communications, Marketing and Creative Services
Dalhousie University
Cell: 1-902-220-0491
Email: alison.auld@dal.ca