The performance of electrode materials in lithium-ion (Li-ion), sodium-ion (Na-ion) and related batteries depends not only on their chemical composition but also on their microstructure. The choice of a synthesis method is therefore of paramount importance. Amongst the wide variety of synthesis or shaping routes reported for an ever-increasing panel of compositions, spray-drying stands out as a versatile tool offering demonstrated potential for up-scaling to industrial quantities. In this review, we provide an overview of the rapidly increasing literature including both spray-drying of solutions and spray-drying of suspensions. We focus, in particular, on the chemical aspects of the formulation of the solution/suspension to be spray-dried. We also consider the post-processing of the spray-dried precursors and the resulting morphologies of granules. The review references more than 300 publications in tables where entries are listed based on final compound composition, starting materials, sources of carbon etc.
A disodium cobalt(ii) orthosilicate material has been synthesized using improved solid-state and co-precipitation methods of synthesis. The Rietveld refinement of the XRD pattern of Na2CoSiO4 demonstrated an orthorhombic crystal system.
A hydrothermal synthesis route was used to synthesize iron(III) phosphate hydroxide hydrate-carbon nanotube composites. Carbon nanotubes (CNT) were mixed in solution with Fe(PO)(OH)(HO) (FPHH) precursors for one-pot hydrothermal reaction leading to the FPHH/CNT composite. This produces a highly electronic conductive material to be used as a cathode material for Li-ion battery. The galvanostatic cycling analysis shows that the material delivers a specific capacity of 160 mAh g at 0.2 C (0.2 Li per fu in 1 h), slightly decreasing with increasing current density. A high charge-discharge cyclability is observed, showing that a capacity of 120 mAh g at 1 C is maintained after 500 cycles. This may be attributed to the microspherical morphology of the particles and electronic percolation due to CNT but also to the unusual insertion mechanism resulting from the peculiar structure of FPHH formed by chains of partially occupied FeO octahedra connected by PO tetrahedra. The mechanism of the first discharge-charge cycle was investigated by combining operando X-ray diffraction and Fe Mössbauer spectroscopy. FPHH undergoes a monophasic reaction with up to 10% volume changes based on the Fe/Fe redox process. However, the variations of the FPHH lattice parameters and the Fe quadrupole splitting distributions during the Li insertion-deinsertion process show a two-step behavior. We propose that such mechanism could be due to the existence of different types of vacant sites in FPHH, including vacant "octahedral" sites (Fe vacancies) that improve diffusion of Li by connecting the one-dimensional channels.
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