As part of Project 2 of NXTGEN High-Tech Energy, E-magy is developing a process for producing nanoporous silicon material for lithium-ion battery anodes. Currently, production stands at approximately 35 kilograms per week, but to effectively serve the market, a much larger scale is needed. That is why E-magy’s focus within this project is on scaling up this process. We spoke with Ian Bennett, Senior Process Engineer at E-magy, about this.

Scaling Up with Silicon

Silicon is a new material in the battery industry, which is currently most familiar with graphite. Because silicon is not yet widely used, it must first be demonstrated that it can perform better technically and also be more economically attractive to manufacturers. For this reason, the material is currently being sent to potential customers for testing in their own processes. Based on those results, the team will determine what further adjustments are needed.

The first steps toward scaling up have already been taken. E-magy is now producing about 35 kilograms per production run. The goal is to increase this even further to 300 kilograms per run by the end of 2026. This won’t happen on its own. A major challenge is that the current machine is now more than 15 years old and was originally designed for a different process. As a result, new components must be integrated with older software and technologies, which adds to the complexity.

When it comes to machinery, it’s clear that E-magy needs a new generation of machines. That’s why they’re already looking into new components and the development of the next-generation machine. The modifications currently being tested are primarily intended as a stepping stone toward the next-generation machine. This allows them to test the components in advance, before a completely new machine is built.

Challenges of Using Silicon in Batteries

Silicon’s great promise lies in its high capacity, but it also carries risks—particularly in the interaction between silicon and the electrolyte. This can lead to degradation. One possible solution is to combine silicon with graphite, but doing so also results in a loss of some capacity. E-magy is therefore investigating various electrolytes and is also exploring coatings and alternative coating methods to limit the interaction between silicon and the electrolyte.

Within the Netherlands, there are several companies working on silicon anode materials. E-magy does not immediately see this as a problem. “In fact, it can help build credibility for this technology. If multiple companies can demonstrate that silicon is the next step in battery materials, it will strengthen market acceptance. After that, it remains important for a company to differentiate itself in terms of process, costs, performance, and scalability,” says Ian.

E-magy stands out because of the way its material is produced. They use a casting process in which silicon is cast into slabs and then ground into powder. For E-magy, this is a relatively simple process, and it has the advantage of not requiring silane gas. The end product is a loose powder that battery manufacturers can easily use in their existing production lines as a substitute for graphite.

NXTGEN High-Tech

The goal of this NXTGEN Hightech project is to further develop the current machine into a version capable of continuous operation. The concept has already been developed, and the engineering phase is currently underway. Ultimately, this will lead to an upscaling to a production capacity of >50 metric tons per year.

The ultimate goal is to scale up to tens of metric tons per year by 2028/2029. This will initially be achieved with a single machine, after which production can be expanded further by adding more machines. Depending on customer demand, it is also possible to scale up to an optimized production capacity of >300 metric tons per year by 2029/2030.

NXTGEN Hightech facilitates this scaling up. This is made possible by making the development of new components and modifications to machines a realistic possibility. NXTGEN Hightech thus ensures that small-scale development can grow into large-scale production. In addition, the network associated with this NXTGEN Hightech project is also of great value.

As Ian explains: “There’s a similar partner involved in the project. This can sometimes be challenging, but it’s also very valuable. Within this project, we learn from each other and work together to ensure that the market can continue to open up. In addition, we’re collaborating on coatings and anode materials, and we’re working with other partners on ways to improve the material’s functionality.”

Outlook

Another step is planned for 2027: the replacement of larger parts of the system, such as the melting unit and the transport components. This will pave the way for a more continuous process.

Once this NXTGEN Hightech project is complete, a logical next step for E-magy would be to launch another similar project, but one that is more focused on the next generation of machines.

About NXTGEN Hightech

This project is made possible in part by a grant from the National Growth Fund’s NXTGEN Hightech program. With more than 330 partners, across more than 60 projects, and in six key areas, this program will make a significant contribution to structural and sustainable economic growth in the Netherlands and provide solutions to major societal challenges in the areas of energy transition, health, safety, and food.

Including the €450 million contribution from the National Growth Fund, NXTGEN Hightech will invest approximately €1 billion by 2030. With this investment, we will create a world-leading ecosystem for high-tech equipment in the Netherlands—one that ranks among the top three in Europe and contributes an additional €6 to 11 billion annually to the Dutch GDP. We will develop a new generation of high-tech machines and equipment for the future generation of Dutch citizens: our children. For more information, visit www.nxtgenhightech.nl