Powall is a deep-tech company that uses Atomic Layer Deposition (ALD) to apply extremely thin layers to powder particles. In addition to Project 2, Powall is also a consortium partner in Project 8. In this article, we take a closer look at Powall’s role in Project 2: Next-Generation Equipment for Batteries and Battery Materials. To that end, we spoke with Sanjana Chandrashekar, Project Manager at Powall.

Cathode and Anode Powders

As part of the NXTGEN Hightech project, Powall applies very thin coatings to silicon anode and cathode battery powders. The use of coatings is not new in the battery industry. They are applied to both cathode and anode materials using various processes. In this project, Powall aims to scale up a unique nano-coating technology based on ALD.

Applying extremely thin and conformal layers to powders is one of Powall’s unique strengths. While ALD is typically used on flat surfaces, Powall can apply the protective layer directly to the powder itself before it is processed into electrodes. As a result, the coating can be applied more consistently across the powder particles. Powall does not produce the powders itself, but collaborates with E-magy—also a consortium partner—among many other commercial partners in the battery industry.

Coatings

The coatings applied by Powall protect the battery material from degradation. As a result, batteries can last longer. Coatings can extend battery life, as evidenced by the increasing number of charge and discharge cycles the battery can undergo before its performance begins to decline.

ALD enables Powall not only to apply simple coatings, but also to develop more complex coating materials. In the battery industry, coatings such as aluminum oxide and titanium oxide are primarily used. With Powall’s technology, it is also possible to apply more complex coatings, such as combinations of lithium and aluminum.

These possibilities give Powall more leeway to experiment with new coating materials. Sanjana adds: “This is important because new cathode and anode materials are constantly being developed. When a new battery electrode material is used, it is likely that a different coating material will also be needed to make it work. In that sense, nanocoatings can enable top-notch materials—for example, those with higher capacity or faster charging—that otherwise could not be commercialized without a coating.”

Powall has also found that the coatings extend the shelf life of the powders. This means that the powders can be produced and stored without losing their performance or properties.

Scaling Up

Scaling up is an important part of this project. Powall is working to scale up even further. Currently, three different units have been validated: one unit with a capacity of 1 kilogram per hour, one unit with a capacity of 10 kilograms per hour, and one unit with a capacity of 100 kilograms of powder per hour.

For use in large-scale battery production, such as gigafactories, the scale must be increased even further. In that case, Powall will likely need a unit capable of processing about 1,000 kilograms per hour. Sanjana explains: “This is technically feasible, because the scalability of the technology has already been demonstrated.”

A recent challenge in this scale-up has less to do with the technology itself and more with the production of the units. Powall has the technology and expertise, but finding suitable engineering partners in the Netherlands capable of building the units proved to be a challenge. That is why Powall is building a unit at NXTGEN Hightech in South Korea. Sanjana explains: “This has led to a significant reduction in production costs for the units.”

NXTGEN High-Tech

Powall joined this NXTGEN Hightech project because it gives them the opportunity to further develop their knowledge and technology for the battery materials market. They have already seen strong interest from companies that produce active materials. This project allows Powall to build further expertise in production scaling and to expand their market reach.

The project's relevance to the battery sector in the Netherlands lies in leveraging Dutch technology to improve battery performance.

As part of the project, Powall is collaborating with various partners, such as the University of Twente and TU Delft. These partners have specific techniques to help Powall better understand what is happening in the coating materials being developed.

Sanjana adds: “The project has been a positive experience so far. Collaboration within the consortium has been strong, and the exchange of information has been good. We are looking forward to the next steps in the project.”

 

About NXTGEN Hightech
This project is made possible in part by a grant from the National Growth Fund program NXTGEN Hightech. With over 330 partners, more than 60 projects, and six key domains, this program will make a significant contribution to structural and sustainable economic growth in the Netherlands and offer 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. In doing so, we will establish a world-leading ecosystem for high-tech equipment in the Netherlands, which will rank among the top three in Europe at a minimum and contribute an additional €6 to 11 billion per year to Dutch GNP. We will develop a new generation of high-tech equipment for the next generation of Dutch people: our children. For more information, please visit www.nxtgenhightech.nl