Optimized synthesis of ultra-small particle size Ni0.94Co0.04Mn0.02(OH)2 precursors for nickel-rich single-crystal cathode materials via reactor configuration and process parameter modulation

Nickel-rich single-crystal cathode materials have become a research hotspot in power battery. However, preparing highly dispersed Nickel-rich small-sized precursors with excellent sphericity using stirred tank reactors remains a major challenge. Therefore, it is essential to clarify the influence mechanisms of reactor structural parameters and co-precipitation operating condition on the crystalline characteristics of ultra-small particle size precursors. In this study, computational fluid dynamics simulations were employed to elucidate the impact of impeller type, impeller elevation, and baffle quantity on mixing efficiency within the reactor. This systematic analysis identifies the optimal combination of internal components that ensures uniform flow field distribution. Under optimal reactor structural parameters, optimized co-precipitation process parameters enabled the successful preparation of ultra-small particle size precursor with excellent sphericity and crystallinity. The derived single-crystal cathode material demonstrated good electrochemical performance. This research provides theoretical foundation and process optimization guidance for the industrial production of ultra-small particle size nickel-rich single-crystal precursors.