The role of E-magy within NXTGEN Hightech

Within project 2 of NXTGEN Hightech energy, E-magy is developing a process for making nano-porous silicon material for lithium-ion battery anodes. Currently, production is about 35 kilos per week, but to properly serve the market, a much larger scale is needed. Therefore, the focus of E-magy within this project is on scaling up this process. We discussed this with Ian Bennett, Senior Process Engineer at E-magy.

Scaling up with silicon

Silicon is a new material in the battery sector, as the current sector is mainly familiar with graphite. As silicon is not yet widely used, it must first be proven that silicon can technically work better and also be economically more attractive to manufacturers. Therefore, the material is currently being sent to potential customers for testing in their own processes. Based on those results, it will be determined what adjustments are still needed.

The beginning of the scaling-up process has already been initiated. E-magy is now at about 35 kilos per production run. The goal is to further increase this to 300 kilos per run by the end of 2026. This does not happen automatically. One important challenge is that the current machine is already more than 15 years old and intended for a different process. As a result, new components need to be integrated with older software and techniques, which makes it more complex.

In terms of machinery, it is clear that E-magy needs a new generation of machines. Therefore, they are already looking into new components and the development of the next-generation machine. The adjustments currently being tested are primarily intended as a stepping stone to the next-generation machine. This way, they can already test the components before building a complete new machine.

Challenges of silicon in batteries

The great promise of silicon lies in its high capacity, but it also comes with risks. Especially in the interaction between silicon and electrolyte. This can result in degradation. A possible solution is to combine silicon with graphite, but this also means giving up some of the capacity. E-magy is therefore investigating different electrolytes and also looking into coatings and alternative coating methods to limit the interaction between silicon and electrolyte.

In the Netherlands, several companies are working with silicon anode material. E-magy does not see this as a problem. “It can actually help build credibility for this technology. If several companies can demonstrate that silicon is the next step in battery materials, it strengthens market acceptance. After that, it remains important for the company to differentiate itself in terms of process, cost, performance, and scalability.” says Ian.

E-magy differentiates itself by the way the material is made. They use a casting process where silicon is cast into wafers and then milled into powder. This is a relatively simple process for E-magy and has the advantage that no silane gas is needed. The end product is a loose powder that battery manufacturers can easily use in their existing production line as a replacement for graphite.

NXTGEN Hightech

The goal within this project of NXTGEN Hightech is to develop the current machine into a version that can continuously operate. The concept has already been developed for this, and the engineering phase is underway. Ultimately, this will lead to a scale-up to a capacity of >50 tons of production per year.

The ultimate goal is to scale up to tens of tons per year around 2028/2029. This initially with one machine, after which it can grow further by placing more machines. Depending on customer traction, it is also possible to scale up to an optimized production of >300 tons per year in 2029/2030.

NXTGEN Hightech facilitates this scaling up. This is made possible by making the development of new components and adjustments to machines realistic. Thus, NXTGEN Hightech ensures that small-scale development can grow into large-scale production. In addition, the network of this NXTGEN Hightech project is also of great value.

As Ian says, “There is a similar partner in the project. This can sometimes be exciting but also very valuable. Within this project, you learn from each other and together ensure that the market can be further opened. In addition, there is cooperation in the field of coatings and anode material, and we work with other partners on ways to improve the functionality of the material.”

Outlook

A further step is planned for 2027. Replacing larger parts of the installation, such as the melting unit and transport components. This way, a more continuous process can be developed.

After this NXTGEN Hightech project, it is a logical step for E-magy to start a similar project again, but more focused on the next-generation machine.

About NXTGEN Hightech

This project is made possible by a contribution from the National Growth Fund program NXTGEN Hightech. This program will invest up to €1 billion with over 330 partners in more than 60 projects across six essential domains by 2030. NXTGEN Hightech thus makes a significant contribution to structural and sustainable economic growth in the Netherlands and provides solutions to major societal challenges in the areas of energy transition, health, safety, and nutrition. For more information, also check www.nxtgenhightech.nl