Statistical approach to design Zn particle size, shape, and crystallinity for alkaline batteries

doi:10.1007/s11708-024-0904-1

Front. Energy

2024, Vol. 18

Issue (5) : 650-664 https://doi.org/10.1007/s11708-024-0904-1

Statistical approach to design Zn particle size, shape, and crystallinity for alkaline batteries

Brian Lenhart¹, Devadharshini Kathan¹, Valerie Hiemer^1,², 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

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Abstract

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.

Keywords zinc anode battery optimization capacity corrosion

Corresponding Author(s): William E. Mustain

Online First Date: 10 January 2024 Issue Date: 16 October 2024

Cite this article:

Brian Lenhart,Devadharshini Kathan,Valerie Hiemer, et al. Statistical approach to design Zn particle size, shape, and crystallinity for alkaline batteries[J]. Front. Energy, 2024, 18(5): 650-664.

URL:

https://academic.hep.com.cn/fie/EN/10.1007/s11708-024-0904-1
https://academic.hep.com.cn/fie/EN/Y2024/V18/I5/650

Fig.1 Scanning electron microscopy (SEM) images of spherical particles representing the 4 size ranges: (a) < 53 μm; (b) 53–106 μm; (c) 106–150 μm; (d)150–250 μm studied, SEM images of the four particle shapes studied: (e) sphere; (f) tube; (g) flat; (h) irregular, and metallography images representing the four particle heat treatments studied: (i) beginning with untreated; (j) RQT420; (k) RQT600; (l) FHT.

Fig.2 Triplicate LSV data for spherical particles in powder form (gravimetrically normalized corrosion current values are reported with their standard deviation values adjacent and coefficient of variation percentages underneath. Rows represent different heat treatments imposed on the particles and the columns represent the different size fractions).

Fig.3 Minitab output plots from statistical analysis of corrosion current data of powder zinc in liquid electrolyte.

Fig.4 Triplicate CCD data for spherical particles in power form (gravimetrically normalized achievable capacity values are reported with their standard deviation values adjacent and coefficient of variation percentages underneath. Rows represent different heat treatments imposed on the particles and the columns represent the different size fractions).

Fig.5 Minitab output plots from the statistical analysis of achieved capacity data for powder zinc in liquid electrolyte.

Fig.6 Triplicate LPR data for spherical particles in slurry form (gravimetrically normalized corrosion current values are reported with their standard deviation values adjacent and coefficient of variation percentages underneath. Rows represent different heat treatments imposed on the particles and the columns represent the different size fractions).

Fig.7 Minitab output plots from statistical analysis of corrosion current data of zinc slurries.

Fig.8 Triplicate CCD data for spherical particles in slurry form (gravimetrically normalized achievable capacity values are reported with their standard deviation values adjacent and coefficient of variation percentages underneath. Rows represent different heat treatments imposed on the particles and the columns represent the different size fractions).

Fig.9 Minitab output plots from statistical analysis of achieved capacity of zinc slurries.

Fig.10 In situ experiments for select Zn powders in slurry form.

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