Sodium-Ion Battery Cathode Active Material Cost Drivers and Manufacturing Scale-up Barriers

Abstract

Energy storage can mitigate challenges posed by intermittent renewable generation. Non-hydro energy storage is currently dominated by lithium-ion batteries, but cost and materials supply are concerns. Sodium is more abundant and cheaper to mine and refine than lithium, positioning sodium-ion batteries to be a potential grid storage solution. However, researchers working at the lab-scale have yet to build consensus around the best sodium-ion battery candidates for commercialization. Cathode active materials (CAMs) are of particular interest because of the pivotal role they play in battery performance and cost. Because of the material class’s simple structure, straightforward synthesis, and potential scalability, layered metal oxides (LMOs) are a particularly promising CAM under study. This thesis investigates the cost drivers and scale-up barriers of LMOs. Processes and equipment considerations influencing scale-up are probed through interviews with experts in industry and academia, and materials and process properties driving the design of critical equipment are identified. A process-based cost model is utilized to investigate the impact of synthesis route on CAM costs at scale, and the materials to total cost fraction for LMOs is found to be significantly lower than that of lithium-ion batteries.