Large Scale Synthesis Methods

Hi again,

While developing active materials for Li and Na-ion battery applications it is always important (imperative?) to also consider economic methods for large scale synthesis and manufacture. It is not really much use to devise new materials that are simply too expensive or too difficult to manufacture at an industrial scale. For example, some years ago we invented the Carbothermal Reduction (CTR) method for large scale synthesis of polyanion Li-ion active materials such as LiFePO4. This still remains one of the very best industry methods for this application and has been used to make many other Li-ion and Na-ion active materials.

Here is a summary of some important large scale synthesis methods I have developed:

Large Scale Manufacturing/Synthesis Methods

Method	Uses	Patent#	Commercialization Status
Carbothermal Reduction (CTR)	Large scale manufacturing synthesis of LiFePO4 and many other Li and Na based transition metal polyanions	US 7060206 US 8163430 and others	Commercialized 2002 1000 MTonne/year production rate Licensed to Li-ion industry (following litigation and patent dispute)
Elemental Red Phosphorus	Excellent method for the large-scale preparation of Li and Na based phosphates	US 10050271	Experimental
Hypophosphite	Excellent method for the large-scale preparation of Li and Na based phosphates	US 10170212	Experimental