Chemicals

Battery Materials

ZSK extruder for the safe production of battery masses with consistently high product quality
ZSK extruder for the safe production of battery masses with consistently high product quality
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ZSK 18 MEGAlab extruder for research and development tasks as well as for the production of small quantities
ZSK 18 MEGAlab extruder for research and development tasks as well as for the production of small quantities
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Coperion K-Tron gravimetric solids feeder in dust-tight design (hepa filter)
Coperion K-Tron gravimetric solids feeder in dust-tight design (hepa filter)
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Coperion offers entire systems from a single source for continuous battery compound manufacturing
Coperion offers entire systems from a single source for continuous battery compound manufacturing
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Producing Battery Compounds

Coperion and Coperion K-Tron offer first-class, reliable technology for manufacturing top-quality battery compounds. As a system provider, our solutions encompass the entire manufacturing process for battery compounds: from bulk material handling to precise feeding and extrusion - including containment concept planning and implementation for every step.

We offer everything you need for your project, all from a single source. With our inhouse planning, engineering, and process expertise, as well as proprietary key components, we can offer individual machine concepts and realize them safely and economically, responding flexibly to all customer- and market-specific requirements all along the way.

Expertise in System Design: From one Single Source

Coperion realizes complete systems — from raw material handling and conveying to feeding and extrusion — all from a single source. Many years of experience and comprehensive process expertise in the areas of system planning, development, and realization make us your ideal partner. We ensure that a corresponding containment concept is developed, planned, and implemented for the entire system.

Continuous Extrusion of Battery Materials

Continuous production can optimize the manufacturing process significantly. The Coperion ZSK twin screw extruder, in combination with high-accuracy Coperion K-Tron feeders, offers high process stability and precision to ensure excellent, reproducible end product quality. Our systems are highly reliable and offer a long service life. Furthermore, continuous production achieves greater material efficiency as well as more cost-efficient and climate-friendly battery cell production compared to conventional batch processes.

Advantages of continuous manufacturing (versus batch processes):

  • Increased profitability
    • Reduced space and personnel requirements
    • High reliability, minimizing downtimes
    • Lower investment costs
  • Tailor-made machine concept and high flexibility
    • Production range between 2 l/h up to 2,000 l/h possible, depending upon machine size
    • Wide variety of recipes possible
  • Extrusion allows for climate-friendly recipes with high proportions of solid content
    • Significant reduction in solvent content or substitution with water in existing recipes
    • Energy use decreases due to shorter drying times
  • Reduced Cleaning Times
    • Continuous processing results in fewer starts and stops, leading to reduced downtimes and machine cleaning
  • Quick recipe changes
    • Ingredient ratios can be changed quickly and easily by modifying feed rates
    • Operators can continuously check product quality and rapidly correct deviations
TYPICAL SET-UP OF A BATTERY LINE
TYPICAL SET-UP OF A BATTERY LINE

TYPICAL SET-UP OF A BATTERY LINE

Suitable materials for every task

Due to the often abrasive and sometimes corrosive properties of the raw materials being processed, the parts of Coperion extruders that come into contact with the product are made of materials offering particularly high resistance to wear.

This makes it possible to avoid contamination of the end product from detached metal particles over the long term, even when processing ultra-hard silicon carbides.

Development of Battery Masses at the Coperion Test Labs. We Help you Optimize your Processes Safely.

Coperion test labs offer you the ideal platform for testing changes or innovations to your products and formulations. In addition to our simulation and scale-up expertise, we have a full range of equipment at our disposal for comprehensive tests and development of processes under realistic production conditions.

When producing battery masses, all experiments are conducted in compliance with local regulations for handling CMR substances.

Markus Fiedler , Process Technology, Teamleader Chemical Applications

In the field of battery masses (anode and cathode slurries), you have the option to carry out customized experiments specific to the question or problem at hand at our Stuttgart Test Lab. Tasks relevant to today’s manufacturing processes, such as switching from batch to continuous production processes while maintaining or even improving end product quality, can be addressed in a controlled environment as well as  questions surrounding maximum solid content of battery slurries or the homogeneity of water-based cathode slurries. Since CMR (carcinogenic, mutagenic, or toxic to reproduction) materials are used in manufacturing cathode slurries, all experiments are conducted in compliance with local regulations for handling CMR substances. Safe handling during use of toxic active materials is thus guaranteed.

Cathode masses experiments at the Stuttgart Test Lab run from raw material feeding to discharge of battery compounds under strictly controlled conditions. Various extruder sizes are available for a wide variety of tasks, such as the ZSK 18 MEGAlab or the ZSK 26 Mc18 extruder for developing new recipes at lab scale, or the ZSK 32 Mc18 or ZSK 40 Mc Plus twin screw extruder for scale-up experiments. Using proven scale-up methods, our process engineers convert test results to production scale. The modular construction of the process section and screw shaft allows tests to be tailored to customers’ requirements and formulations. Machines can even be optimized while operating during trials, thanks to our process engineers’ many years of direct experience. For high-accuracy feeding of ingredients that are not always easy to handle, the lab has access to a portfolio of around 100 gravimetric Coperion K-Tron feeders for solid materials (powder) and liquids.

Moreover, the Coperion Test Lab in Stuttgart has an adjacent laboratory with numerous possibilities for bulk material analysis to immediately evaluate product quality and properties. Among these are viscosity measurement (using a plate-plate rheometer), grindometer, and solid content measurement.

Are you interested in trials at our Test Lab? Then contact us.

Comprehensive product range

Coperion ZSK Extruder

Extruders

The Coperion ZSK twin screw extruder is ideally suited to produce battery masses, as it offers highly dispersive mixing capacity. Subsequent distributive mixing ensures the homogeneity required for high end product quality in battery compounds. The process section’s modular construction allows for flexible and individual modifications to recipes and changes within the process. The extruder’s high conveying efficiency and self-cleaning function increase material efficiency.

ZSK Twin Screw Extruders

Feeding Equipment

Coperion K-Tron’s high-accuracy loss-in-weight feeders are outstanding for highly accurate, reliable feeding of even the most difficult flowing or toxic ingredients. The high, continuous feeding accuracy ensures an optimal end product quality and efficient use of expensive raw materials. Material efficiency due to twin screws’ self-cleaning function and high flexibility due to a fast screw profile changing are further advantages.

For the safe addition of fluids such as binders and solvents, Coperion K-Tron loss-in-weight feeders are articularly well suited as they provide accurate and continuous volumetric or gravimetric flow control for fluids.

Learn also more about the Coperion K-Tron Feeding Technology as the intelligent weighing technology, the electronic pressure compensation or the actiflow bulk solid activator.

Feeding Equipment
Coperion K-Tron Feeding Technology

Material Handling

The Coperion K-Tron P-Series line of pneumatic receivers are ideally suited for the quick and efficient refill of our loss-in-weight feeders. Designs are available for a variety of product pick up options, including drums, IBCs or supersacks. P-Series receivers are available with highly polished product contact surfaces to avoid product build-up and facilitate cleaning. ATEX versions are also available.

P-Series Receivers
Coperion Consulting

Service

Coperion offers comprehensive and efficient services for the delivered machines and systems. With our maintenance services we ensure maximum availability of the systems installed.

Worldwide services

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Production of battery separator films

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High-Performance Battery Cells for Specialized Automotive Applications

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