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Multi-scale simulation for the description of carbon black fragmentation in an extrusion-based dispersion process

Funded by: BMBF

Contact person : Julian Mayer

Summary of the overall project:

MultiEx is a project within the BMBF-funded ProZell competence cluster. The main topic of the investigations is the continuous dispersion process of lithium-ion battery suspensions. Through a coupled CFD-DEM simulation and its experimental validation via suspension and electrode properties, the dispersion process in the extruder is optimized with regard to carbon black structure, throughput and optimal screw configurations. In accordance with the objectives of the overall cluster, the main focus is on the resulting cell quality and performance as well as their costs.

Fig.: Schematic representation of the project contents

Objectives and tasks of the Institute for Particle Technology

  • Production of suspensions in the extruder incl. in-process analysis
  • Improvement and further development of existing analytical methods
  • Production of electrodes by means of a continuous coating machine and their macroscopic characterization with regard to the carbon black structure
  • Electrochemical investigation of the electrodes by using test cells
  • Simulation of extruder twin screw elements on the macro scale as a function of fluid properties and process parameters and derivation of model equations
  • Numerically and experimentally supported optimization of the dispersion process in pilot plant scale
  • Development of a design tool for optimized screw configuration
    Project partners

    Karlsruher Institut für Technologie (KIT): Institut für Mechanische Verfahrenstechnik und Mechanik (MVM)

    Team Members


    S²taR – Development of All-Solid-State Battery Recycling Processes more

    Cooperative project: Project results database and communication management for the battery cell production cluster ProZell (EMKoZell) more

    BaSS – BatterieSicherheitsStandardisierung more

    eKoZell – Environmental and Cost Assessment, Model and Communication Management for the Competence Cluster ProZell – Accompanying Project to the ProZell Cluster (eKoZell) moremore

    Cooperative project: Project results database and communication management for the battery cell production cluster ProZell (EMKoZell) more

    EVOLi²S – Evaluation of the technical and economic advantages of the open-cell module for lithium-ion and lithium-sulphur batteries with regard to stationary and mobile applications more

    Optimal electrode structure and density by design of mixing and calendering procedures (MiKal) more

    MultiDis – Multiscale approach for the description of carbon black deagglomeration in the dispersion process for a process and performance-optimized process control more

    ÖkoTroP – Ecologically gentle dry coating of battery electrodes with optimized electrode structure more

    PräLi – Prelithiation of electrodes more

    ProfiStruk – Process and system development for the process integrated inline structuring of Li-electrodes more

    Process modeling of the calendering of energy-rich electrodes (ProKal) more

    Roll-It more

    LiPlanet – Li-ion cell pilot lines network moremore

    LoCoTroP – Low cost dry coating of battery electrodes for energy efficient and environmentally friendly production processes more

    Sim4Pro- Digitalization Platform – Simulations for battery cell production more

    ZiLsicher – Zink-Air-Accumulators as safe electrochemical storage for low emission and explosion proof industrial applications more

    Finished Projects
    BenchBatt – Process based energy optimization and validation of Lithium-Ion and Lithium-Sulfur battery electrodes more

    GEENI – Graduate Program for Energy Storage and Electromobility more

    INSIDER – metal free Dual Ion energy storage technology utilizing anionic -intercalation more

    Academic Initiative for e-Mobility – Education and Training in the University Network MOBIL4e more

    ProLiEMo – Production Research for High-Power Lithium-Ion Batteries for Electro Mobility  mehr

    Functional Materials and Material Analysis for High Power Lithium-Ion Batteries more

    LithoRec – LithoRec – Recycling of Lithium Ion Batteries mehr