Statistical approach to design Zn particle size, shape, and crystallinity for alkaline batteries
Brian Lenhart1, Devadharshini Kathan1, Valerie Hiemer1,2, Mike Zuraw3, Matt Hull3, William E. Mustain1()
1. Department of Chemical Engineering, University of South Carolina, Columbia, SC 29208, USA 2. Department of Chemical Engineering, Virginia Polytechnic Institute, Blacksburg, VA 24060, USA 3. Duracell, Bethel, CT 06801, USA
In modern alkaline batteries, the zinc anode is the performance-limiting and lifetime-limiting electrode, making the choice of zinc powder critical. Due to the various material fabrication processes that are used to manufacture industrial zinc powder, there exists a wide array of possible zinc particle shapes, sizes, and crystallinities. These industrial zinc powders are typically conceived, produced, and tested through trial-and-error processes using historical “rules of thumb.” However, a data-driven approach could more effectively elucidate the optimum combination of zinc particle properties. In this paper, the effect of Zn particle size, shape, and crystallinity on the achievable capacity and corrosion current is investigated. The Zn types are tested in both powder and slurry form. Following the data collection, a factorial-based statistical analysis is performed to determine the most statistically significant variables affecting capacity and corrosion. This information is then used to down-select to a subset of particles that are tested in cylindrical cells with an AA-equivalent geometry. The reported technique can be used to develop actionable principles for battery manufacturers to create cells that are more stable, longer lasting, and have higher energy densities.
. [J]. Frontiers in Energy, 2024, 18(5): 650-664.
Brian Lenhart, Devadharshini Kathan, Valerie Hiemer, Mike Zuraw, Matt Hull, William E. Mustain. Statistical approach to design Zn particle size, shape, and crystallinity for alkaline batteries. Front. Energy, 2024, 18(5): 650-664.
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