Slug-flow-based continuous manufacturing of Fe-substituted Ni-rich NCM cathodes for lithium-ion batteries: synthesis and modeling

Continuous production of good quality low-cobalt Ni-rich cathode is needed as it can offer high capacity suitable for electric vehicles. However, the low-cobalt NCM-based materials suffer from a high cation mixing and poor rate capability. Also, proper optimization of co-precipitation reaction parameters as well as the manufacturing platform are needed to obtain NCM-precursor particles with uniform particle size and morphology. In order to address all the issues, in this work, a slug-flow-based manufacturing platform is utilized for the continuous production of Fe³⁺ substituted Ni_0.85Co_(0.1−x)Mn_0.05Fe_xC₂O₄ (where x = 0, 0.02, 0.04) precursors. The slug-flow manufacturing produces precursor particles with high yield and uniformity. The effect of reactants concentration on the product yield and composition is analyzed through mathematical modelling. Finally, the electrochemical performance of the Ni-rich cathodes with various amounts of Co and Fe content is analyzed through rate capability, cycling stability, and impedance analysis. This work provides key insight into: (i) reactor design for continuous production; (ii) mathematical modelling of the precipitation reaction parameter; and (iii) a detail study of the effect of Co-substitution with Fe³⁺ in Ni-rich NCM on its physical properties as well as electrochemical performance. We find that an intermediate Fe content provides optimum cathode with desired properties.