You’re facing major challenges in producing these cathode active materials (CAM) and anode active materials (AAM). Scaling up processes from lab development to commercial production is complex. Rapid market growth requires quick profitability, and constant innovation is essential to remain competitive. At the same time, increasingly stringent environmental regulations require optimized, sustainable production processes to meet the industry’s current and future challenges.

To prevent contamination, which can result from factors such as abrasion, corrosion, oxidation or the quality of reagents or unreacted materials, it’s vital to consider numerous precautions right from the design phase. Precise reagent dosing, selecting the appropriate main filtration equipment and construction materials as well as effective inerting and process control strategies are therefore essential for ensuring product quality. You need to establish efficient and robust processes that will ensure both the profitability and viability of your operations. Partnering with specialists with cutting-edge expertise is crucial to achieving this.

At BBA, we stand out for our expertise in designing process plants to produce CAMs and AAMs, a highly complex skillset mastered by few. Our goal is to design and optimize manufacturing processes to produce high-quality, ultra-pure active materials at lower costs.

BBA is also involved in refining and producing the inputs necessary for the battery industry. We work with your suppliers—such as those providing lithium hydroxide, lithium carbonate and cobalt hydroxide—to ensure the quality and purity of the raw materials used in the production of your CAMs and AAMs.

We also have the expertise to support you through every stage of your project, from mineral extraction and refining to battery recycling.

Collaboration with suppliers of raw materials for cathode active materials

We work closely with suppliers of materials used to produce CAMs. This collaboration helps us leverage our knowledge of water handling, purity and treatment issues. We focus on the material value and strive to limit losses through smart technology choices.

• Selection of the right materials to guarantee purity
• Optimization of processes to reduce operating costs
• Development of technologies to reduce losses
• Water treatment

Commercial scale-up of laboratory-developed technologies

With our expertise in pyrometallurgy and hydrometallurgy , we support our clients in scaling up their processes, from laboratory development to pilot plant, and ultimately to commercial production. We make sure to select and validate the production technologies used, applying advanced techniques to guarantee optimal results at every stage of the process.

• Support at every step of the process scale-up
• Technology selection to enhance industrial performance
• Cost optimization for investments and production during scale-up
• Ongoing monitoring and adjustments to guarantee quality and efficiency

Design for corrosive and high-temperature environments

We create complete solutions for corrosive environments and high-temperature applications. When managing toxic gases, explosive dust and abrasion, our integrated approach promotes the sustainability of complex chemical environments while ensuring the safety of your team. Our onsite presence helps us optimize your designs based on your operational reality and objectives.

• Design of iterative solutions
• Holistic approach incorporating sustainability, environmental quality, health and safety
• Onsite optimization for enhanced performance

Process optimization for production

We focus on optimizing production processes to reduce waste and improve energy efficiency. By integrating advanced technologies and applying proven strategies, we help our clients maximize yield while lowering production costs and minimizing the environmental impact.

• Contamination risk management
• Waste reduction in production processes
• Process adjustments to improve plant energy efficiency
• Integration of advanced technologies to optimize production
• Application of best practices to reduce operating costs
• Adoption of sustainable solutions to minimize environmental impact

Commissioning and operational support

We offer full commissioning and operational support to ensure optimal plant performance. Our onsite presence ensures an in-depth understanding of the equipment and technologies being used. We’re proficient in key production stages, including reaction control, drying technologies, calcination, spheronization, crystallization and particle milling.

• Onsite presence for ongoing operational support
• Process optimization to maximize productivity and reliability
• Continuous industrial performance analysis and improvement
• Proactive maintenance to prevent production interruptions
• Performance monitoring for continuous improvement
• Consistent technical support to optimize your operations
• Safety and compliance for safe operations