Producing Battery Compounds

Coperion provides ideal feeding and extrusion technology for producing a wide variety of battery components. The focus is on the continuous production of electrode materials and separator films.

Ensuring consistently high product quality is one of the key advantages of the continuous production of battery compounds. Active materials, binding agents, conductive carbon and liquids are used as raw materials. These are fed either via independent Coperion K-Tron feeders or premixes. Precise adherence to the formula ensures the high quality of the end products. Certain raw materials are partly toxic and/or abrasive. For this reason, processing in the Coperion ZSK extruder takes place under controlled conditions, from feeding the raw materials through to discharging the compound. Feeding the raw materials with dust-tight equipment is just as important as avoiding metal contamination in the end product. Furthermore, ZSK extrusion systems intended for producing battery compounds are designed in compliance with stringent explosion protection regulations due to the raw materials.

Benefits

  • High system reliability and flexibility
  • Production under controlled conditions
  • Process stability to ensure high product quality
  • Dust-tight equipment design to ensure safe processing of harmful substances in the production of cathode compounds
  • Avoidance of metal contamination in the end product using special materials for the screw elements
  • Long operating time
  • High mixing behavior, homogeneity
  • System design in accordance with explosion protection regulations

Single Source

With Coperion and Coperion K-Tron you have the support of a partner who can assist with all your extrusion, feeding and conveying tasks. We supply both single components and complete systems: You can obtain everything from one single source, from raw material handling through to feeding, extrusion and conveying. Our product lines are designed to meet strict requirements for use in industry. We supply our customers, leading companies and research institutions with specialist technical solutions for all tasks – always focusing on safety, product and process quality.

Continuous Extrusion of Battery Materials

Coperion supports you in switching from a batch process to continuous production of cathode and anode compounds, as well as the manufacture of battery separator films and electrode compounds for solid state batteries. In conjunction with high accuracy Coperion K-Tron feeders, Coperion ZSK twin screw extruders boast high reliability, long operating times and numerous properties that ensure a high and reproducible end product quality. Continuous production enables greater material efficiency and optimized, more cost-efficient battery compound production to be achieved.

Advantages of continuous extrusion (compared to batch processes):

  • Excellent cost-effectiveness
  • Production range between 1 kg/h and 2,500 kg/h possible
  • High and reproducible end product quality
  • Significant reduction of solvent content in existing recipes
  • Environmentally friendly manufacturing after adaptation of recipes (due to reduced solvent content)
  • Easy processing of highly viscous compounds
  • Extremely short cleaning times and material efficiency due to self-cleaning effect of the twin screw extruder
  • Reduction in space and personnel requirements
  • Short residence time in the extruder – little thermal stress on the material
  • Reliable devolatilization, even of materials that are difficult to devolatilize
  • Excellent feed behavior, even when processing raw materials with low bulk density

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.

Coperion_Markus_Fiedler

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

Coperion offers highly productive ZSK twin screw extruders for the continuous production of cathode and anode masses, as well as separator films. Conveying, mixing, shearing and the homogenization essential for obtaining products of a consistently high and reproducible quality standard take place in processing zones that are optimally designed for the processes concerned.

ZSK Twin Screw Extruders
Coperion_K-Tron_new_pharma_feeder_K3-PH_835x470px

Feeding Equipment

Coperion K-Tron’s loss-in-weight feeders are ideally suited for the highly accurate and reliable delivery of even the most difficult flowing ingredients used in the manufacture of electrode compounds and separator films. The K3-PH line of Coperion K-Tron feeders feature a highly polished product contact surface finish and state-of-the-art sealing design to meet the strict requirements of battery applications. In addition, the quick clean design reduces cleaning time and improves flexibility.

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

Rotary Valves

Especially the chemical industry produces many different bulk materials that have various and sometimes difficult product properties.

Through decades of experience and with the comprehensive process know-how in systems engineering, Coperion rotary valves offer reliable process technology solutions that secure a consistently high product quality.

The rotary valve series ZZB is specifically designed for challenging and hard-to-handle materials in continuous production processes.

Rotary Valve ZZB

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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