EDWARD BUIEL CONSULTING LLC — Department of Energy SBIR Phase II: 14a

Description

This project will develop state-of-the-art processes for the conversion of natural flake graphite and other graphitic materials into high quality lithium-ion battery (LIB) grade anode materials. This will enable a $1B industry to develop and create a supply chain for graphite that does not exist in the United States today. This project will complete 4 years of work by Coulometrics to develop new environmentally friendly and low cost processes for the conversion of graphitic materials into a high quality LIB anode material that exhibits: Lower cost; Improved purification through an environmentally friendly process, and; A high quality and consistent material suitable for demanding electric vehicle applications. Currently, all natural graphite for lithium ion batteries originates in China. This represents the most profitable value-added market for graphite with no current beneficiaries in the US. This is true even though vast high-quality flake graphite deposits of exist in the US and Canada and the US also boasts some of the highest quality petroleum coke that can be used to produce synthetic graphite. Many junior graphite and petroleum companies are eager to see their materials used for LIB anode material however new state-of-the-art process technologies are required that will: Spheronize the graphite with higher yield than what is currently used in China; Purify the spheronized and synthetic graphite, and; CVD coating of the spheronized graphite to provide high efficiency and long life in LIBs.Coulometrics has increased spheronization yield from 30 to 70%, demonstrated new thermal purification technologies that achieve record graphite purity, and developed a new CVD coating process that has allowed us to achieve unprecedented LIB life even when compared to world class cells used in Tesla vehicles today. Coulometrics graphite anode materials meet all automotive specifications including high capacity (>355 mAh/g) and high first cycle efficiency (92-95%).Coulometrics is already working with leading US battery manufacturers and has included letters of support for this effort from Tesla Motors and K2 Energy. We consider each a beachhead customer for both automotive and military markets that are the focus of our commercialization plan. The goal of our Phase II effort is to continue the development of our graphite products that focus on longer life, higher charge rate and resistance lithium plating, and cost reductions through process innovation. Coulometrics is currently able to build and test 2.4 to 3.0 Ah 18650 cylindrical lithium ion batteries and performance state-of-the-art high precision coulometry testing to determine life and charge rate capabilities. This work is also being validated by our commercial partners and we are sending full 18650 cylindrical cells for verification. Full qualification and a current target price of $4-5/kg will make this material very attractive to LIB manufacturers who are currently paying more than $14/kg in high volume. Coulometrics has established a new joint venture called PUREgraphite with Graphitecorp that has funding the commercialization effort with $10M. Coulometrics will continue to develop the material and owns 50% of PUREgraphite.