Winds of Change: The Role of Spray Drying in the Green Energy Revolution

Welcome back to the “Colorful Researchers” blog. In my last post, I discussed how our latest freeze-drying solution, the Lyovapor™ L-250, increases the sustainability and efficiency of the freeze-drying process. In this post, I would like to discuss how another one of our instruments contributes to a more sustainable future. 

In Argentina, we have a fantastic source of sustainable energy production. The strong winds in Patagonia are ideal for power generation; however, there is one major problem. Patagonia lies 1500 km from the large cities where the energy demand is concentrated. Storing and transporting energy from sustainable energy generation sites like hydro dams, wind farms, and tidal energy generators is the bottleneck in many of these sustainability solutions. Large-scale battery storage solutions are required to store and transport this energy for use when needed. 

What types of batteries are required for the green energy revolution?

Vast research is currently being done on battery technology due to its importance in transitioning to a sustainable future. Modern batteries fall into two general categories: those used for consumer goods and electric vehicles (EVs) and those for stationary storage. Batteries for consumer goods and EVs must be compact, lightweight, have a high capacity, and charge quickly. Stationary batteries can be larger but must be robust and not rely on unsustainable materials; otherwise, their environmental impact undermines the very purpose of renewable energy. If the batteries rely on unsustainable materials or suffer degradation requiring constant replacement, they risk negating the benefits of clean energy production.

How can modern batteries be made more sustainable?

The desire to increase sustainability has led to iron emerging as a crucial material for battery development. Iron-based compounds like iron (III) hydroxyfluoride play a key role. Iron is abundant, cost-effective, and more ethically responsible than the cobalt and nickel traditionally used in lithium-ion batteries. The shift to iron-based batteries reduces reliance on scarce, harmful materials. It offers a scalable and greener solution for energy storage, particularly for large-scale renewable energy applications like wind, tidal, and solar power.

What are the challenges of creating robust and reliable batteries?

Using sustainable materials is only part of the equation. The durability issue must be addressed so batteries can perform consistently over long periods. To tackle this issue, researchers are developing solid-state batteries that use solid electrolytes instead of liquid ones. Solid electrolytes are more stable and help prevent the growth of dendrites by providing a more uniform path for lithium ions to travel. 

Dendrites are branch-like structures that develop during charging and discharging cycles and can cause short circuits and battery failure over time. Solid electrolytes like lithium lanthanum zirconium oxide (LLZO) are more stable and help prevent dendrites from forming. Innovations like the bilayer LLZO membrane, which combines porous and dense layers, help reduce current density and stop dendrites from penetrating the battery’s electrodes, extending the battery’s life and making them more reliable for mass energy storage and transfer.

How is spray drying used to create advanced battery technologies?

Spray drying technology plays a pivotal role in producing advanced battery materials. By converting liquid precursor solutions into fine, consistent powders, spray drying ensures precise control over particle size and morphology, essential for the uniformity and efficiency of battery components like iron-based compounds and solid electrolytes such as LLZO. Spray drying enables controlled material composition and scalability, making it suitable for industrial production while maintaining fast drying times and energy efficiency. The technology supports the customization of coatings and layers, which are crucial for optimizing electrode surfaces, reducing processing time, and ultimately improving the electrochemical performance of the final battery product.

What issues do battery developers face?

In the production of modern batteries, particularly those involving lithium, exposure to moisture and oxygen can be highly detrimental due to the reactive nature of lithium. When lithium comes into contact with oxygen, it reacts immediately to form lithium oxide (Li₂O). This reaction degrades the lithium material and reduces the yield.

Similarly, when lithium meets water (or moisture in the air), it reacts to form lithium hydroxide (LiOH) and hydrogen gas (H₂). This reaction can be hazardous, as the hydrogen gas produced is flammable and poses a risk of fire or explosion in the production environment. The formation of lithium hydroxide also reduces the amount of active lithium available, lowering the efficiency of the battery materials being produced.

In both cases—whether lithium is exposed to oxygen or moisture—the reactivity leads to contamination of the battery materials, resulting in a lower yield and potential safety hazards. Controlling the environment during production is crucial to maintaining the quality, safety, and efficiency of the materials used. This issue is dealt with by our Mini Spray-Dryer S-300, which shields samples from environmental contaminants using a closed mode (under inert conditions). 

How do our instruments meet the needs of modern battery production?

When searching for ways of further improving our systems, we realized that customers faced a dilemma during product removal and transfer. To address this, we created the Enviro Guard accessory. The Enviro Guard accessory uses an advanced glass system featuring a stopcock and gas inlet that introduces Argon, a dense noble gas, to create an inert atmosphere around the sample. Argon has a higher density than air, making it ideal for displacing oxygen and moisture, effectively preserving the integrity of delicate battery powders. After drying, the Enviro Guard allows for carefully removing and transferring materials to a glove box for further processing, with oxygen and moisture levels kept below 2% for up to five minutes. This level of control ensures sample integrity throughout the production.

Combining innovative spray drying technologies like the S-300 and cutting-edge accessories like the Enviro Guard helps move the battery industry forward in its quest for more sustainable solutions. 

For specialists like me, it’s thrilling to be at the intersection of materials science and sustainability, attempting to bridge the gap between nature’s raw power and the growing energy demands of urban life. I am hopeful that modern technologies can harness the renewable power of the wind in Patagonia and deliver it to the cities where it’s needed most.

In the world of spray drying and sustainable technology development, every small advancement helps make the bigger picture possible.

Bueno Chao,
Bruno