Project Selections for FOA 3105: Critical Material Innovation, Efficiency, and Alternatives (Set 2)

Area of Interest 5: Alternative Products

Commercialization of Power Dense Nanocomposite-Based Rare Earth Element-Free Axial Flux Electric Motors. CorePower Magnetics (Pittsburgh, Pennsylvania) plans to develop and prototype a high-performance rare earth element-free electric motor utilizing nanocrystalline soft magnets and a unique flux-switching motor design to achieve a combination of high torque, efficiency, and power density. Through the design and optimization process, the project will evaluate and compare several rare earth element-free permanent-magnet technologies for performance and production readiness. Given that many of the available rare earth element-free permanent-magnets have drawbacks when compared with rare earth element permanent-magnets, the project will consider flux switching with permanent magnets motor topology because of its ability to address these property deficiencies. The first period of the program will focus on mechanical failure analysis and tailoring custom optimization and analysis tools to best handle the properties of several rare earth element-free permanent-magnet in motor design optimization. This period will also include a multi-objective design optimization and evaluation of the readiness of novel rare earth element-free permanent-magnet production. The second program period will include highly refined electromagnetic, mechanical, and thermal analysis of the selected motor design to increase confidence in prototype performance. The final project period will focus on prototype construction using advanced manufacturing techniques intended to enable large-scale manufacturing and prototype testing throughout its operating range.

DOE Funding: $958,722
Non-DOE Funding: $241,080
Total Value: $1,199,802
 

Low-Cost Cathode Materials for Long Cycle, High Energy Density Na-ion Batteries. Giner, Inc. (Auburndale, Massachusetts), with project partners Northeastern University and Ampcera, Inc., plans to develop layered transition metal oxide cathodes with high capacity, high operating voltage for sodium (Na)-ion battery systems (NIBs) using abundant and domestically available elements such as manganese, iron, titanium, and magnesium, and reducing the use of elements such as copper or nickel. The goal is to provide rechargeable batteries for electric vehicle applications with lower cost and sustainable battery chemistry, along with sufficient energy density to enable wide-scale adoption of NIBs for electric vehicles. Giner will pair O-3 type layered transition metal oxides cathodes with advanced electrolytes and commercially available hard carbon anode to demonstrate NIBs. Giner will develop new electrolytes and additives to mitigate surface reactivity of layered oxide cathode to enhance the stability of cathode-electrolyte interface, which will help to achieve long cycling stability (>1000 cycles). Northeastern University will focus on P2-type cathode development, structural, and surface characterization to fully evaluate the capabilities of developed O-3 and P-2 type layered oxide materials. Ampcera Inc. will focus on developing a scale-up process and demonstrating scalability and material quality. Giner will evaluate electrochemical performance of developed cathode materials in the single-layer pouch cells using advanced electrolyte and commercially available hard carbon anode. 

DOE Funding: $999,950
Non-DOE Funding: $250,000
Total Value: $1,249,950
 

High-Performance Sodium-ion Batteries Utilizing Domestic Coal- and Waste Coal-derived Hard Carbon Anodes. Ohio University (Athens, Ohio), with project partners the University of Cincinnati, CONSOL Innovations, Koppers, NEI Corporation, Cyclikal, Forge Nano, and Mortenson, plan to develop coal and waste coal-derived hard carbon anodes that, when coupled with domestically sourced cathode materials, will result in a next-generation high performance sodium-ion battery (SIB). To date, the United States has relied heavily on imports of lithium-ion batteries (LIB). While investments are now being made to increase U.S. LIB manufacturing capacity, many of the materials for these batteries must be imported. The SIB is a promising “beyond lithium” battery chemistry, because sodium is more abundant than lithium, the use of cobalt is not needed, and the battery cost is potentially much lower. Hard carbon is the most promising SIB negative electrode and can be synthesized from many carbon sources. This project addresses the need to develop domestic materials and stand-up manufacturing capacity for SIBs by developing domestic supply chains for critical battery materials. Hard carbon is an alternative energy storage material to graphite and can be synthesized from low-rank coal and coal waste to create an advanced domestic energy storage material. The project will engage Appalachian community stakeholders to provide feedback on the use of coal and coal waste in the region to develop these energy storage materials and investigate workforce impacts.

DOE Funding: $999,980
Non-DOE Funding: $23,000
Total Value: $1,022,980
                                   

A Domestic Critical Material Solution: Abundant Graphite Anode Substitute for Lithium Batteries. Semplastics (Oviedo, Florida), with project partners CONSOL Innovations and C-BATT, plans to develop an alternative anode active product (AAP) to serve as a battery-grade graphite substitute in LIBs, intended for use in grid storage applications. This project can improve the domestic availability of key components in grid storage batteries, while also removing potentially hazardous coal waste from the environment. The team will leverage its previously developed technology to produce high-performance silicon oxycarbide (SiOC) coal-composite AAPs using domestically sourced, highly abundant, low-cost coal feedstocks. The project will develop, qualify, and optimize a more environmentally and economically sustainable SiOC waste coal fines (WCF) AAP system to serve as an alternative substitute for battery-grade natural graphite. The project will culminate in demonstration of the ability to produce the SiOC WCF AAP on a semicontinuous basis and validation of performance in prototype pouch full cells of at least 500 milliampere-hour capacity. A life cycle assessment, a techno-economic analysis, and feasibility studies will be done to show the benefits of the streamlined production methods. The study will compare project metrics to those of battery-grade natural graphite produced overseas and evaluate the SiOC WCF AAPs to establish the viability of this technology for grid storage applications.

DOE Funding: $999,998
Non-DOE Funding: $253,420
Total Value: $1,253,418
                       

High Energy and Cycling Stable All-weather Aqueous Zn Batteries. University of Tennessee (Knoxville, Tennessee) plans to develop alkaline-manganese dioxide (Zn-MnO2) batteries using minerals with robust supply chains in the United States as an alternative technology to LIBs, which are costly and are developed almost exclusively on imported minerals and components. The project will fundamentally re-design Zn-MnO2 batteries and unlock the rechargeability in environmentally benign neutral electrolytes with energy densities comparable with LIBs. The alkaline version of these batteries is commercially manufactured in large quantities in the United States primarily as non-rechargeable batteries, and the alkaline electrolyte is highly corrosive. The project innovation is focused on development of novel electrolytes, and specifically electrolyte additives, that can simultaneously stabilize both the cathode and anode interface during long cycling across a wide range of temperatures. Prototypes will be assembled both as lab scale coin cells and pilot scale cylindrical cells and systematically evaluated. Ultimately, this project aims to demonstrate significantly improved cycling stability both at high (50℃) and freezing (-40℃) temperatures and provide feasible gateways toward practical deployments for commercialization. When combined with low-cost solar panels, the technology can provide feasible solutions to deliver carbon-free clean electricity to U.S. communities.

DOE Funding: $523,830 
Non-DOE Funding: $0
Total Value: $523,830

Direct Upcycling of Mixed Ni-Lean Polycrystals to Single Crystal Ni-Rich Cathode Materials. Worcester Polytechnic Institute (Worcester, Massachusetts), with project partner Koura, to develop an upcycling approach where pure or mixed nickel (Ni)-lean polycrystal cathode materials will be reused to produce a higher quality product by converting them to Ni-rich single crystal cathode materials, which will help to ensure a robust supply chain for the battery industry. The process will implement a one-step molten salt method to convert spent polycrystalline Ni-lean cathodes into single-crystal Ni-rich cathodes, which could then be applied to either pure or mixed cathode streams without additional sorting and separating steps. After discharging, shredding or dismantling, and separation of cathode and anode, the mixed spent Ni-lean cathode materials could be converted to Ni-rich single-crystal cathode materials, which exhibit improved capacity and stability compared to the commercial materials.  This process will also further reduce the battery material and reduce carbon dioxide emissions of the battery industry. If successful, the project will revolutionize lithium-ion battery recycling technologies, increasing U.S. competitiveness in the global lithium-ion battery industry. 

DOE Funding: $1,000,000
Non-DOE Funding: $0
Total Value: $1,000,000