Committed To Quality, Committed To You
Lithium-ion batteries in the modern world are made up of cathode powders like LFP, NMC, NCA and LCO. These powders are important because of the performance, safety and lifecycle of a battery. Although processes like calcination or coating often get the spotlight, one of the most important but overlooked processes is cathode powder screening. This process has a direct effect on material consistency, slurry stability, and eventually, battery performance.
The process of developing cathode active materials is carried out in a series of well-planned steps. The first step is combining and weighing (i.e., metering) the required quantities of the chemically pre-cursor metal oxides (and lithium compounds) for each. The blend is then placed in high-temperature furnaces for calcination, where crystal structures form, giving each material its unique electrochemical properties.
Once calcined, the resulting material is normally coarse, granular, or lumpy when it comes out of the furnace. To prepare it for downstream use, manufacturers reduce it to fine powder through crushing and milling. The aim is to generate a uniform particle size distribution (PSD) which enhances effective electron and ion movement in the ultimate battery cell:
These defects can negatively affect material flow, coating uniformity and energy density.
The first step in producing cathode powder is the milling process. Once the powder is milled, the powder must go through the screening process to ensure the powder meets the particle size and purity requirements before it can proceed to the slurry stage. Using a good quality screening system allows for the following:
Having a consistent particle size distribution (PSD) will reduce the chances of segregation, increase the packing density of the powder, and improve the contact area of the powder with the particles. This uniformity of PSD is important for battery performance.
Tough agglomerates or large particles might hurt the machines, hinder the mixing of slurry or cause defects during the coating of electrodes.
Foreign material, metal fragments, dust or process residues can cause cell failure or internal short circuits. Screening acts as a protective barrier against such risks.
High-value materials such as cathode powders require strong and precise screening equipment. The SIVTEK SUPER GYRO SEPARATOR® has been designed for the toughest jobs where screening is necessary.
The main advantages are:
High Throughput with Fine Accuracy
The machine’s advanced gyratory motion ensures maximum material spread across the mesh, improving screening efficiency even at finer mesh sizes.
Superior Handling of Sticky or Fine Powders
Cathode materials often exhibit poor flow or cohesive behaviour. The Super Gyro Separator maintains consistent movement, preventing screen choking or powder buildup.
Uniform Screening Across Multiple Decks
When manufacturers require multiple cuts such as D50 or D90 control the separator can classify materials across several mesh layers in a single pass.
Stable Operation with Low Maintenance
Its rugged build handles continuous, heavy-duty battery manufacturing environments with ease.
Although this blog focuses on powder processing, it’s important to highlight the direct benefit screening provides to the next stage. When powders are clean, uniform, and devoid of oversized particles, the process of mixing the slurry is:
To summarize, high-quality cathode slurry is produced from high-quality screened powder.
The production of cathode powders is a complicated process, but screening is a deciding factor. Using high-performance screening solutions like the SIVTEK SUPER GYRO SEPARATOR®, manufacturers have tighter control over powder purity, consistency, and particle structure. This single step not only improves the quality of the powder but also increases the performance of the slurry and the overall efficiency of the battery.
