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Solid-state batteries milling Equipment

Milling machines are used to reduce the size of material by cutting, crushing, or grinding it. The choice of industrial milling equipment depends on the industry and the materials to work with. Besides, there is a significant difference between those aimed to remove layers from metal or other materials workpieces and those designed to reduce particle size for materials that come in bulk.

Milling

The inventor of the lithium-ion battery predicted that solid-state batteries would become commercially available by the mid-2020s, making them an attractive option for energy storage in a wide range of applications, including electric vehicles. This battery type promises a marked improvement in safety, power, and environmental impact compared to current battery packs that use a liquid electrolyte. However, recent breakthroughs in the lab don’t automatically translate into mass production. The complex processing requires specially-designed manufacturing technology to make solid-state batteries a real solution, especially for the automotive industry.

Solid-state batteries

For grinding soft products up to a Moh´s hardness of 3.5. The end products are free from oversize particles and have a steep particle size distribution and an exact top cut.


<h2>Designed for processing sticky products that tend to deposit</h2>
The Classifier Mill - ZPS Zirkoplex from Hosokawa alpine is a universal classifier mill for materials to a Moh´s hardness of approx. 3 when the requirements call for extremely high end-product fineness values at the lowest possible energy consumption.

It works by rejecting the particles that are too coarse by the classifying wheel and are comminuted by the beater unit until they can pass through the classifying wheel and thus correspond to the required fineness as specified by the classifying wheel speed.

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Classifier mill for soft products

For pre-crushing before fine grinding, non-fine crushing, sharp-edged granules, and narrow granule distribution. With high-pressure roller mills products are produced with a precipitous granule distribution.


<h2>Compact mills for sharp-edged granules</h2>
The high-pressure roller mill from Hosokawa Alpine is also called roller crusher or roller press. In comparison to compaction processes, it uses lower press forces between the rollers because no new adhesive forces need to be created.

With high-pressure roller mills products are produced with a precipitous granule distribution.

Because only the outer particles of the material bed have contact with the surface of the rollers, milling that is almost contamination-free is possible.

Often used in the cases of medium-fine crushing of hard materials such as ceramics, minerals from 5 up to 9 on the MOHS hardness scale metals and metal alloys.

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High pressure roller mill

High-quality powder coatings are often required to manufacture equipment, appliances, and vehicles to ensure product durability and longevity. A combined dry grinding and classifying system can significantly help to improve the quality of powder coatings production by providing steep particle size distribution. To achieve the finest uniform powder coatings, the mixture of pigment, polymer resin, and other additives must be finely pulverized.


<h2>Classifier mill to grind brittle material dry, free-flowing, and fine powders</h2>
The Impact Classifier Mill ICM by NEUMAN &amp; ESSER is designed for grinding brittle material to superfine particles such as materials for powder coatings. It combines efficient impact grinding and precise classification technology. During impact grinding, grinding tools throw feed materials into the liner and crush it. The classifier separates coarse particles and sends them back to the mill’s grinding zone for further grinding. It effectively achieves grinding cuts and narrow particle size distribution of 20 μm to 1,000 μm. The throughput of the various mill sizes and designs can range from 10 kg/hr to 20,000 kg/hr. In addition, the large grinding chamber has cooler temperatures that result in lower fines generation.

The ICM employs direct drive technology, a type of permanent-magnet synchronous motor. It removes using a gearbox and oil supply in its rotor, making the mill easy to operate and clean. In addition, the mill is pressure shock resistant up to 11 bar, a must when grinding for powder coatings.

Classifier mill for powder coating

To facilitate the attainment of ultrafine particles and enhance electrode properties, reactivity, and surface structure proper grinding technology and high-quality raw materials should be applied.
<h2>Offers grinding and dispersion for NMC, Li-NMC, LNMC, and NCM materials</h2>
DYNO<sup>®</sup>-MILL Universal Bead Mill (UBM) from WAB-GROUP<sup>® </sup>provides dispersion and ultra-fine grinding solutions for a wide range of battery materials from laboratory-scale to large-scale production.  The mill is scalable with a grinding chamber volume from 0.5 to 100 l while using grinding media between Ø 0.2 and 2.5 mm. It is suitable for dispersion and grinding of battery materials like anode and cathode materials, fuel cells, carbon nanotubes, multi-layer ceramic capacitors, and photovoltaic and separator materials.

It comprises the DYNO<sup>®</sup>-DISC BC agitator discs, featuring grinding media channels, which ensure efficient acceleration of the media along a precisely defined path. While in operation, each of the bead channels establishes two grinding circuits between the agitator discs, functioning in opposing directions. The closed outer contour secures the grinding beads between the agitator discs and uniformly distributes them within the active grinding chamber, for dispersion and fine grinding of battery materials.

Ultrafine bead mill for battery materials

In battery production, a critical phase entails mixing solids with liquids. To achieve optimal performance, minimizing agglomerates in the coating masses is vital. This necessitates a homogeneous dispersion of particles in the coating slurry, comprising solvents, binders, and adhesive materials. Nevertheless, traditional procedures continue to face persistent challenges, such as clumping and undissolved powder residues on unwetted tank surfaces.


<h2>Fully enclosed batch mixing system for fuel cell and battery</h2>
The CMX 2000 inline mixer from IKA incorporates powders into liquids in an enclosed and complete system. It mixes the liquid solvents homogeneously with solids ensuring consistent product and dispersion quality with concentrated energy input.

Featuring a dosing feeder for solids and recirculation technology, the solution limits the mixing process to one machine and reduces the potential for emissions.

The multi-level pump is designed to keep high-viscosity materials flowing without leaving deposits in the mixing container. The chemicals are recirculated to ensure consistent blending and prevent the formation of agglomerates in the final mix.

Solid may be fed with a bulk bag unloader, a hopper, sack-emptying boxes, or directly from the bag with a suction lance. The CMX 2000 is available for batch sizes between 2 and 5.000 liters.

Inline solid-liquid mixer for battery production

Landline telephones in the 1980s were minimalist gadgets that kept getting slimmer in the 1990s. In contrast, cell phones in the same period were bulky and cumbersome. And once they lost their charge, they turned into a giant paperweight. Then came a revolution in batteries and automation with lithium-ion battery manufacturing equipment. Mobile phones packed more power, recharged faster, and endured more recharge cycles. Above all, they were light and small, making cell phones the inseparable companions they are today. But Lithium-ion batteries power much more than phones. As a result, the world is seeing steady growth in battery manufacturing equipment and lithium-ion production lines.

Lithium-ion batteries

Built upon its world-leading laboratory equipment, IKA Process is a game changing manufacturer of dispersing machines, homogenizers, stirrers, jet flow agitators, and kneading machines.

Anything below a 50-micrometer speck of dust falls out of the visual acuity of the human eye. Yet, we can still perceive the effects of the things we cannot see.

The coating process for lithium-ion batteries is a case in point. The complex paste of binders, conductive agents, and active particles is coated a few micrometers thick on a conductor, but the presence of lumps can impair the batteries’ performance.

The critical process in achieving homogeneous coating slurry is mixing. However, mixing is never just mixing, as we’ve learned from Ralf Bürgelin, process expert at <a href="https://www.linkedin.com/company/ika-works" target="_blank" rel="noopener">IKA Process Equipment</a>. The most important factor is to get particles well dispersed and this can be accomplished by conducting the mixing process in-line.


<h2>Increase energy to keep solids apart</h2>
“<em>Ingredients like binders and carbon powders tend to agglomerate in liquid</em>,” Ralf explains. These materials float on the surface and clump together as soon as they are introduced to a liquid phase.

Agglomerate formation is a problem for all slurry materials, but battery coating layers are applied at the micrometric scale, and imperfections are significantly amplified. Aggregates can vary in size, ranging from large to small. Big aggregates can result in scratches on the coating surface, while small aggregates can decrease the battery's performance.

This is a main hurdle for conventional mixing to overcome. But IKA is no conventional technology provider: “<em>We solve the challenge of agglomeration by conducting the dispersion inline within a small chamber in a high turbulence zone</em>.” The intensity keeps the solid particles apart and distributes them uniformly throughout the liquid medium.
<h2>Reduce space in the mixing chamber to regulate particle motion</h2>
Besides energy, there is also the question of volume. When powders are released in large mixing vessels like planetary mixers, particles can escape. By contrast, IKA guides the liquid mixture in a small chamber where particles have no room to escape. This allows IKA to exert more precise control over the dispersal.

But doesn’t this high-energy mixing in a confined space generate excessive thermal stress on the materials?

“<em>Temperatures should not rise over 50° C</em>,” warns Ralf. In fact, the standard mixer from IKA operates at room temperature and rises to around 30-40 degrees as the mixture recirculates.

In line mixing, high turbulence, and a small chamber. These parameters are the levers that ensure a stable coating paste without agglomerates. Even though the active layer is smaller than a speck of dust, the quality of the lump-free coating is for all to see.

Saying goodbye to lumps in battery coating paste

Chemical

The battery revolution is as old as the industrial revolution. But batteries only emerged as a viable power source with lithium-ion solutions in the last quarter of the 20<sup>th</sup> century. Today, anything from power tools to automobiles runs on batteries, but advances in battery making equipment are eyeing more ambitious undertakings. Will we ever see battery-powered container ships? Will Battery Energy Storage Systems grow grid-scale successfully? Production technology is steadily moving towards this vision.

Batteries

Due to their potential hazardous nature, chemicals are classified for proper identification and safety during production. Chemical classification depends on their properties, structures and functions. In the chemical industry, you can regard them as basic chemicals such as acids, chemical products to produce plastic materials and finished chemicals for use in cosmetology. As a manufacturer or engineer, you want to know their reactivity when using chemical processing equipment.

Chemicals

Powder containment is the cornerstone of chemical and pharmaceutical manufacturing. Floating particles do not only represent efficiency loss but serious hazards too. Lack of tightness during the powder discharge process leads to cross-contamination and operational health risks.


<h3>Dock transfer systems squarely in place</h3>
The ASBV active/passive valve interface by Andocksysteme locks into position, minimizing exposure of material during powder discharge. The system has two split valves – one active, one passive – that can be easily and reliably centred on each other at a tolerance of ± 14 mm.

Once the units are docked, the valve discs open simultaneously, preventing exposure of the products during transfers. The dust-tight environment achieves contamination values lower than 1µg/m3.

The ASBV solution is fitted with EPDM seals and are optional with a wide range of materials, such as PTFE, offering top-range chemical resistance. All seals are made from FDA-approved materials and can handle a wide range of temperatures as well as explosion-proof executions.

Washing the ASBV interface is simple as the system can be connected to a WIP loop to flush out residual powders. These containment solutions serve applications with an exceptional performance and are easy to be integrated. Moreover, high quality parts and reduced complexity drives simple maintenance.

High containment split butterfly valve

Andocksysteme is a specialist in developing and engineering high-quality containment docking and solutions for bulk material.

In 2023, the New York City Fire Department mounted a 200-firefighter operation to put out a massive residential blaze. It was only one of 130 fires in a year caused by a lithium-ion battery failure.

LIB devices catch fire when dendrite formation punctures the membrane separating the electrodes, shorting the circuit. The thermal pressures that develop from this excessive flow of current only need milliseconds to release the energy packed in the battery cells and explode.

If a battery containing a few grams of chemical solutions is enough to mutate a phone into a pocket bomb, handling the materials in bulk can turn a battery production facility into an inferno.


<h3>Exposure to impurities is playing with fire</h3>
The risks of combustion are especially high during the discharge process. Many of the production steps are performed in a contained environment, but the dispensing areas expose the materials to the elements.

If airborne particles and oxygen come into contact with the mixture, they destabilize the delicate chemical composition. Given the power density per batch, a small amount of impurities is enough to generate unforeseen reactions that could quickly burst into flames.

But in theory, such accidents are preventable. Handling materials in a closed system should keep them away from contamination.

It is <a href="https://andocksysteme.de/en/" target="_blank" rel="noopener">Andocksysteme</a>’s job to translate this theory into practice. The containment technology company is at the forefront of safe handling solutions.
<h3>A closed system is as strong as its high-containment valve</h3>
The risk profile of battery production mixtures hinges directly on the valve interface. In fact, discharge stations are the Achilles heel of a closed system and quality valves keep the process safe.

The perfect valve technology for battery manufacturers involves multiple layers of protection against contamination. The construction material is critical, which is why Andocksysteme builds its interfaces from inert stainless steel.

Another crucial factor is seal technology. With a reliable locking mechanism and tight-fitting seals the active-to-passive valves match together perfectly to avoid cross-contamination of these toxic fine powders. Moreover, the valve system must integrate into an automatic dispensing process typically deployed by manufacturers.

Seamless high-volume production is vital to an industry that is growing so fast. Indeed, the LIB manufacturing market is on fire. The right containment technology ensures that hazardous substances (powders) are transferred safely and operators are well protected.

Material discharge should be no burning issue for battery manufacturers

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Solid-state batteries milling

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Solid-state batteries milling Equipment

Which solid-state batteries milling technology do you need?

Classifier mill for soft products

High pressure roller mill

Classifier mill for powder coating

Ultrafine bead mill for battery materials

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