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Leclanché: Environmentally Friendly Li-Ion Batteries on the Verge of a Breakthrough?

The newly developed cells are expected to deliver 20 percent more performance. The use of NMCA cathodes with high specific capacity reduces the cobalt content of the electrodes to five percent. 

The new G/NMCA cells have an energy density that is 20% higher than predecessor products. (Photo: Leclanché)
The new G/NMCA cells have an energy density that is 20% higher than predecessor products. (Photo: Leclanché)
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Johannes Reichel
von Claus Bünnagel

Leclanché has achieved a breakthrough in the environmentally friendly production of modern G/NMCA cells. According to the company, the Swiss manufacturer is the first worldwide to reduce the cobalt content in NMCA electrodes from the previous 20% to 5% using an environmentally friendly water-based process. Leclanché completely avoids the use of the highly toxic organic solvents (NMP) commonly used in the production process. According to the manufacturer, the new G/NMCA cells have 20% higher energy density than previous products, while maintaining the same size, weight, and high performance. NMCA cathodes based on water-based binders are easier to dispose of and recycle.

With the water-based production of high-capacity NMCA cathodes, we have reached a crucial milestone in lithium-ion technology. Until now, their production using environmentally friendly methods was considered impossible. But now we have mastered the process. (Dr. Hilmi Buqa, Vice President of Research and Development)

Nickel content around 90%

According to their own information, Leclanché is the first company worldwide to implement the environmentally friendly process in the production of Li-Ion cells. The newly developed G/NMCA cell has a nickel content of around 90%, which increases energy density and allows for a significant reduction in cobalt content by 15%. At the same time, it offers a longer lifespan, high cycle stability, and good charging capability. Thanks to the high volume density and high cycle stability, the new cells are not only particularly suitable for electric cars but also for heavy-duty applications such as ships, buses, and trucks.

Leclanché's water-based production process

High-capacity NMCA cathodes (nickel-manganese-cobalt-aluminium oxide) enable a 20% increase in the energy density of a Li-Ion cell compared to conventional G/NMC cells. However, most manufacturers produce these cathodes using organic solvents like NMP (N-Methylpyrrolidone). These are highly toxic and environmentally damaging. In April 2018, NMP was added to the list of substances of very high concern that can have serious irreversible effects on human health and the environment. The use of NMP has therefore been restricted by the European Commission.

In contrast, Leclanché has been using aqueous binders in its production process for around 13 years and is a world leader in this field. In the technically simpler process, no organic solvents are used. This not only eliminates the risk of explosions, but also ensures no health hazards for employees in the production process. Another advantage: thanks to the water-based process, Leclanché can avoid energy-intensive processes for drying, venting, and recycling of solvents. With 10-30% lower energy consumption, the Leclanché process also improves the CO2 footprint of battery cell production.

Production in Germany

Leclanché is one of the few independent manufacturers of lithium-ion battery cells in Europe. The large-format cells are 100% produced in Germany at the Willstätt site in Baden-Württemberg. Module production takes place on a state-of-the-art automated assembly line at the company's headquarters in Yverdon, Switzerland. Unique in Europe are both the long-standing experience and the depth of the production chain: Leclanché possesses the complete know-how for the production of high-quality lithium-ion cells – from electrochemistry to battery management software and the combination of battery systems – thus covering the entire technical value chain. The new environmentally friendly G/NMCA cells from Leclanché are expected to be available on the market in 2024.

Translated automatically from German.
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