Online Process Control for Sustainable Battery Manufacturing & Recycling

Achieve Industry 4.0 Efficiency with Malvern Panalytical Solutions

Learn more how industry 4.0 solutions can support sustainable battery manufacturing.

The surge in electric vehicles has propelled battery manufacturing to new heights, and this trend is expected to continue. However, cost pressures demand constant innovation to reduce waste and ensure consistent quality. This applies not only to production, but also to battery recycling, which must be profitable despite fluctuating prices for key materials like lithium and nickel.

Industry 4.0 solutions can significantly address these challenges. Malvern Panalytical offers a suite of online process control tools that span the entire battery manufacturing value chain, empowering smarter factory processes. These solutions provide crucial insights for:

  1. Particle size analysis in precursor and electrode materials production
  2. Elemental composition analysis of liquid precursors during production and recycling
  3. Analyzing electrode coatings
  4. Determining the orientation index of graphite-coated electrodes
  5. Elemental composition analysis of black mass for recycling

Online particle size control to minimize process waste

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Online particle size analyzer for battery precursors and electrode materials
 

Insitec Range

Online particle size control to minimize process waste


Insitec systems deliver the online continuous particle size analysis needed for efficient, cost-effective monitoring and control of industrial processes. Suitable for the widest variety of process streams from dry powders to hot sticky slurries, sprays and emulsions, whether milligrams of material or hundreds of tonnes per hour. Insitec systems measure particles in the size range 0.1 micron to 2.5 mm.

 

Insitec Dry

Benefit from the revolution in the studies of biomolecular interactions

Insitec Wet

The industrially robust, technologically proven process particle size analyzer.

Insitec Spray

The industrially robust, technologically proven process particle size analyzer for sprays and aerosols.

 

Very good instrument for wet analysis of the sample.

Diwakar Shende— Visvesvaraya National Institute of Technology Nagpur
Epsilon XFlow

Online elemental composition analysis of liquid precursors

On-line liquid analysis with the Epsilon Xflow gives the solution for fast and accurate control of your process parameters. Increased regulations and quality specifications drive the need for a continue process flow. The Epsilon Xflow enables real-time insight to manage your production processes more efficient and reduce operational costs.

 
Epsilon Xline

In-line elemental composition analysis of electrode coatings

On-line liquid analysis with the Epsilon Xflow gives the solution for fast and accurate control of your process parameters. Increased regulations and quality specifications drive the need for a continue process flow. The Epsilon Xflow enables real-time insight to manage your production processes more efficient and reduce operational costs.

Online XRD

Controlling the orientation index in graphite electrode coatings

On-line liquid analysis with the Epsilon Xflow gives the solution for fast and accurate control of your process parameters. Increased regulations and quality specifications drive the need for a continue process flow. The Epsilon Xflow enables real-time insight to manage your production processes more efficient and reduce operational costs.


 

Explore our Application Lab

Epsilon Xline makes real-time materials monitoring and process control in roll-to-roll (R2R) coating processes a breeze. Direct analysis allows continuous optimization of material composition and loading, helping to minimize off-specification production and maximize cost-efficiency.


 

Online process control solutions:

Our latest articles about battery manufacturing and recycling
Webinar
 
Insights

Optimizing battery performance with precise particle sizing & structure of materials

Malvern Panalytical and NETZSCH Grinding and Dispersion will host a webinar entitled Battery Performance with Particle Sizing and Structure of Materials webinar! Learn from experts how analytical techniques such as laser diffraction particle sizing can support the process of jet milling. Jeff DeNigris, Business Domain Specialist for Batteries, MP will be presenting details of integrated online particle size analysis and the use of the data for process control. Jeff will be accompanied by NETZSCH Energy Solutions Applications Manager, Matthew Hughes who will be presenting details on milling solutions and types of processes used in LiB manufacturing.

Insights
 
Insights

Insitec: bringing the energy transition on-line

Placed right at the center of today’s industrial and societal innovation, the battery industry is experiencing an unprecedented boom, driven by the search for efficient, fast-charging, and durable power sources. And while innovators and manufacturers work meticulously to optimize the chemical compositions of their products, there’s one crucial aspect that can’t be overlooked: particle sizing.

Insights