About NOVONIX™ Cathode Materials
NOVONIX’s cathode materials group has developed a patented all-dry, zero-waste cathode synthesis process for nickel-based cathode production with the target of servicing the rapidly expanding electric vehicle and energy storage sectors.
Patented all-dry, zero-waste technology
NOVONIX has commissioned a 10 tonnes per annum (tpa) pilot scale facility capability to demonstrate the scalability of its patented, all-dry, zero-waste cathode synthesis process for NMC cathode production. A commercial-scale engineering comparison study conducted by Hatch Ltd. estimated potential improvements over the conventional process:
- Capital expense intensity estimated nearly 30% lower
- Processing cost reductions estimated nearly 50% lower
- Estimated power consumption improvements of approximately 27%
- Removes the need for water in the material processing steps
- Eliminates other key waste byproducts including sodium sulphate
Dive deeper and learn about NOVONIX's all-dry, zero-waste cathode synthesis technology
With the growth of electric vehicles and energy storage systems in North America, the need for a sustainable domestic supply chain for lithium-ion battery components is urgent. NOVONIX has developed a patented cathode synthesis process that eliminates the co-precipitation step, reducing water usage, waste, and costs.
The NOVONIX process carries several benefits over the conventional method of cathode synthesis:
- Simplified production flow
- Decreased unit operations
- Lower power consumption
- 30% reduction in capital expense intensity
- Nearly 50% (excluding feedstock) lower processing costs
The pilot production, housed in a 35,000-square-foot-facility, allows NOVONIX to demonstrate large-scale production of up to 10 tpa.
Cathode cycle performance meets industry standard
The pilot line has produced a mid-nickel grade of single-crystal cathode material (NMC622) using the company’s patented all-dry, zero-waste synthesis technology that matches the performance of leading cathode materials from existing suppliers in full-cell testing.
Enhanced production process yields consistent performance
- NOVONIX all-dry, single-crystal cathode materials share similar morphology to commercial NMC powders
- Higher nickel and cobalt-free materials are also being made using NOVONIX’s process technology
NMC622 cathode cycle performance competitive with commercial material
Normalized electrochemical results in 1Ah pouch cell show that NOVONIX NMC622 has comparable electrochemical performance to commercial NMC materials.
Our zero-waste cathode synthesis process
With multiple patent applications filed, NOVONIX’s patented cathode synthesis process delivers NMC cathode synthesis technology for materials that are drop-in ready with conventional nickel-based cathode powders.
Current Cathode Synthesis Processes
- Complex
- Costly
- Uses significant amounts of water per tonne of cathode powder generated
- Chemical inputs required
NOVONIX’s Process
- Flexible input materials
- Higher yields at lower cost
- Elimination of process wastewater and sodium sulphate byproduct generation
- Lower power consumption
The market outlook
NOVONIX is actively developing innovative battery materials that enable simplified and improved performance, as well as more environmentally sustainable manufacturing processes necessary for the North American battery ecosystem. The Company is committed to improving the production of high performance, high-nickel cathode material through its patented process while providing scalable solutions that address soaring battery materials demands.
The overall market for cathode active materials is expected to be over $100 billion by 2030 with 10% of that market allocated towards processing. With the battery industry continuing to focus on cost reduction and more sustainable processes, the opportunity for NOVONIX’s cathode synthesis process is readily apparent.
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