Powall is a deep-tech company that leverages Atomic Layer Deposition (ALD) to apply extremely thin layers onto powder particles. Besides Project 2, Powall is also a consortium partner within 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. For this, we spoke with Sanjana Chandrashekar, Project Manager at Powall.

Cathode and Anode powders

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

Applying extremely thin and conformal layers to powders is a unique strength of Powall. While ALD is usually applied to 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 works together with E-magy, also a consortium partner, amongst many other commercial partners from the battery industry

Coatings

The coatings applied by Powall protect the battery material against degradation. As a result, batteries can last longer. Coatings can enhance is the battery life shown by the increasing number of charge and discharge cycles the battery can go through before the performance starts 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 aluminium oxide and titanium oxide are mainly used. With Powall’s technology, it is also possible to apply more complex coatings, such as combinations of lithium and aluminium.

These possibilities give Powall more room to experiment with new coating materials. Sanjana adds: “This is important because there is continuous development of new cathode and anode materials . When a new battery electrode material is used, it is likely that a different coating material will also be required to make it work. In that sense nanocoatings can enable top notch materials, for instance with higher capacity or faster charging, which otherwise could not be commercialized without a coating”

Powall has also seen that the coatings improve 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 trying to scale up even more. Currently, three different units have been validated: one unit for a 1 kilogram per hour, one unit for 10 kilograms per hour, and one unit for 100 kilograms of powder per hour.

For use in large-scale battery production, such as gigafactories, the scale must increase further. In that case, Powall will likely need a unit capable of processing around 1000 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 is less about the technology itself and more about the production of the units. Powall has the technology and expertise, but finding fit for purpose engineering partners in the Netherlands that can build the units was a challenge. That is why Powall is building a unit within the NXTGEN Hightech in South Korea. Sanjana explains: “This has led to a significant reduction in production costs for the units.”

NXTGEN Hightech

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 producing active materials. This project allows Powall to build further expertise in production scaling, and to expand their market reach.

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

Within the project, Powall collaborates with various partners, like 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. The collaboration within the consortium has been strong, and the exchange of information has been good. We are looking forward to the next steps within the project.”

 

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

Including the contribution of € 450 million from the National Growth Fund, NXTGEN Hightech will invest approximately € 1 billion until 2030. In doing so, we will realize an internationally leading ecosystem for high-tech equipment in the Netherlands, which will rank among the top three in Europe at least and make an additional contribution to Dutch GNP of € 6 to 11 billion per year. We will develop a new generation of high-tech equipment for the future generation of Dutch people: our children. For more information, also visit www.nxtgenhightech.nl