Altech Batteries has announced a milestone in its Silumina Anodes technology, achieving an average 55 per cent increase in lithium battery anode energy capacity, building on its previous 30 per cent improvement.

Utilising innovative proprietary technology, Altech has blended alumina-coated silicon particles (10 per cent) with battery-grade graphite to create a composite graphite/silicon anode, the company said in an ASX announcement.  

“We are thrilled with the significant progress we have made in overcoming the critical challenges associated with using silicon in lithium-ion battery anodes,” stated CEO and Managing Director Iggy Tan. 

In a series of tests, Altech’s lithium-ion battery anode material demonstrated an average energy retention capacity of approximately 500 mAh/g, surpassing the typical average of 320 mAh/g for standard lithium-ion battery anodes. 

Altech previously reported advancements in battery technology, highlighting the development of lithium-ion battery anode materials with a retention capacity approximately 30 per cent higher than standard materials. 

Following this progress, Altech’s research and development laboratory in Perth, Western Australia, has been working to enhance the technology even further.

Laboratory tests of the composite graphite/silicon batteries revealed that Altech effectively tackled previously unresolved issues associated with silicon in lithium-ion battery anodes.

Notable challenges included silicon particle swelling, first-cycle capacity loss of up to 50 per cent, and rapid battery degradation. 

Through the spherification of silicon particles, Altech found that the spherical structure allows for better distribution within graphite voids, minimizing damage to the electrode layer due to expansion.

Historically, the use of silicon in commercial lithium-ion batteries has been limited due to two critical drawbacks: the expansion of silicon particles during charging and the deactivation of a significant percentage of lithium ions, which diminishes battery performance and lifespan, the company noted. 

Altech has completed a Definitive Feasibility Study for constructing an 8,000 tpa Silumina Anodes plant in Saxony, Germany, projecting strong economic returns with a pre-tax NPV10 of €684 million and a low capital cost of €112 million.

“Our breakthrough technology represents a major step forward in unlocking the full potential of silicon in lithium-ion batteries, and we believe it has the potential to revolutionise the battery industry,” Tan stated.  

“We are currently commissioning a pilot plant to further scale up our technology and bring it to market,” he concluded.

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Altech Batteries has achieved a key milestone with the successful launch of its CERENERGY ABS60 prototype, a 60kWh battery installed at the Fraunhofer IKTS lab in Dresden, Germany, which, according to the company, is already surpassing initial performance expectations.

The prototype has passed all physical tests, showing remarkable efficiency and stability during daily charging and discharging cycles, Altech said in a media release.  

Integrated into a specially designed battery test station, the unit is undergoing continuous evaluation under real-world conditions. 

The testing aims to assess the battery’s overall performance, providing vital data to support future commercial applications.

Iggy Tan, CEO and Managing Director of Altech, expressed confidence in the breakthrough, stating, “We are extremely pleased that the first CERENERGY® 60kWh battery prototype is now up and running, operating better than expected.” 

He continued, “This reconfirms our confidence in the sodium-chloride solid-state battery technology developed by the world-leading Fraunhofer Institute in Germany.”

Tan emphasised the advantages of CERENERGY® technology, which eliminates the need for lithium, copper, cobalt, graphite, and manganese. 

The sodium-chloride batteries offer a lifespan of 15 years, nearly double that of conventional lithium-ion batteries, and can operate across a wide range of temperatures.

The company further reported that the prototype will continue testing and refinement, delivering critical data for potential off-take agreements as Altech moves closer to constructing a 120MWh production plant. 

With a Letter of Intent for 30MWh of offtake from Schwarze Pumpe Industrial Park already in place, Tan believes the prototype’s success will further support commercial partnerships.

Altech’s joint venture partner, Fraunhofer, also conducted extensive individual cell testing at their Hermsdorf facility. 

A total of 497 battery cells were produced and tested at 300°C. Over 500 cycles, the cells maintained a consistent discharge capacity of 80Ah with an efficiency rate of up to 91 per cent, showing no signs of degradation. 

For further information, visit Altech’s website.

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Altech Batteries has unveiled an opportunity for eligible shareholders to engage in an equity raising initiative through a Share Purchase Plan (SPP), aiming to generate up to $5 million.

The initiative comes hot on the heels of the company’s Definitive Feasibility Study (DFS) for the CERENERGY project, which concluded on 20 March 2024, revealing promising figures including a Net Present Value (NPV) of €169 million and an annual free cash flow of €48 million.

Following the positive outcome of the DFS, Altech said it is progressing towards securing financing for the construction of the CERENERGY battery project, slated to be erected on the company’s property in Germany.

CEO Iggy Tan expressed his satisfaction, stating, “The results of the Definitive Feasibility Study reinforce the economic soundness and potential of our CERENERGY project. We are excited about the positive trajectory and are fully committed to advancing to the funding phase to realise this innovative venture.”

The project’s economic viability remains robust, boasting an EBITDA margin of approximately 47 per cent even at its initial production capacity.

This aligns with the forecasted growth of the grid storage market, projected at an impressive 28 per cent Compound Annual Growth Rate (CAGR).

Moreover, the project presents a competitive edge with a low lifetime levelized cost of storage at €0.06/kWh, significantly undercutting the €0.149/kWh for lithium-ion batteries.

Altech is extending the opportunity to all shareholders to participate in the capital raising via an SPP, aimed at facilitating further activities related to the CERENERGY battery project, as well as the Silumina Anodes TM battery materials project.

Notably, participation in the SPP incurs no brokerage, commission, or other transaction costs for shareholders, allowing all funds received by Alltech to be directly allocated towards commercialising its technology.

With an eye on the burgeoning grid storage market, projected to witness substantial growth amidst the global shift towards renewable energy, Altech said it is racing to bring the CERENERGY battery into production.

Shares issued under the SPP will be priced at $0.065 per share, accompanied by one free attaching option for every two shares acquired.

These options will be exercisable at $0.08 per share and will expire on 30 April 2026.

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Altech Batteries has characterised its advancements as “excellent,” as it undergoes the manufacturing of two ABS60 60 kWh CERENERGY battery prototypes in Germany intended for customer performance testing.

The project, initiated last year, has seen the transformation of battery packs originally developed with 5 kWh and 10 kWh capacities by German research institute Fraunhofer IKTS.

With Altech’s involvement, the focus shifted towards creating a substantial 60 kWh unit tailored for the grid storage market, the ASX-listed company said in a media release.

The manufacturing process, taking place at Fraunhofer IKTS’ pilot line in Hermsdorf, Germany, has undergone extensive redesign and innovation to accommodate the larger battery prototypes.

In particular, the ABS60 battery pack consists of 240 CERENERGY cells, each rated at 2.5 V. These cells are arranged in four rows, stacked five modules high, resulting in a robust and sizable energy storage solution.

The pack’s dimensions are 2.6 metres in height, 0.4 metres in length, and 1.0 metre in width, adhering to the Ingress Protection (IP) 65 standard for dust and weatherproofing.

All materials required for the prototypes have been procured, and the crucial stages of cell production, including ceramic component blending, high-pressure pressing, tube formation, and sintering at 1,600 degrees Celsius, have been successfully navigated.

The ceramic tube production, a critical element, is halfway complete, showcasing the project’s steady progress.

The innovative assembly process involves laser welding tests, vacuum filling, heating, and welding to ensure precise alignment and performance of each cell.

An industrial micro computed tomography (µCT) scanning system is employed for quality assurance, verifying filling height, composition, alignment, and cathode material behaviour post-initialization.

Encouragingly, fifty percent of the required cells have been successfully produced, with low reject or defect rates falling within expected limits.

The Cell Contacting System (CCS), designed by Hofer AG, has been integrated into module frames, demonstrating robust electrical specifications and tolerances.

König Metall GmbH has delivered the battery casings, currently undergoing testing to evaluate heat loss parameters.

As the prototypes near completion, Altech plans to showcase them to potential customers, offering insight into the practical applications and benefits of the ABS60 series in various industries.

This collaboration aims to secure offtake agreements, marking a pivotal step towards the commercialisation of this innovative and sustainable energy storage solution.

The assembly of cells into the battery housing is expected to be finalised by mid-2024, further propelling Altech’s commitment to advancing clean energy technologies.

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Altech Batteries announced a significant milestone in the development of its CERENERGY project, as the company successfully increased the project’s annual production capacity from 100 MWh to 120 MWh.

This achievement is a result of collaborative efforts with the lead engineering company Leadec and joint venture partner Fraunhofer, the company said in an ASX announcement. 

Through technical design optimisation, the plant’s output has seen a remarkable 20 per cent boost without incurring any additional capital expenditures.

As a result, the annual production of 1MWh GridPacks will now reach 120 MWh. Despite the project’s relatively modest size, most equipment sizes used are standard off-the-shelf capacities, providing ample room for increased capacity.

After a thorough evaluation of equipment throughput with each supplier, Leadec has recommended a conservative increase in the plant’s rated output to 120 MWh.

One of the noteworthy updates introduced by Altech is the redesign of the 60 KWh battery pack. The new design features a sleek stainless-steel exterior, replacing the previous blue paint.

This modification enhances the battery pack’s durability and its ability to withstand extreme temperature variations, making it suitable for various environmental conditions, from snowy landscapes to desert climates.

Additionally, a significant breakthrough in the CERENERGY GridPacks design involves the stacking method, allowing for convenient triple stacking and seamless interconnection between each GridPack.

This innovative design facilitates an effortless “plug and play” setup, enabling parallel or series connections to augment operational voltage.

The compact design not only conserves valuable land area but also eliminates the need for separate cooling airflow around the GridPacks, making CERENERGY GridPacks a more advanced alternative to traditional lithium-ion battery solutions.

Altech’s Group Managing Director, Iggy Tan, conveyed that they acknowledged a substantial margin in the various equipment designs right from the start.

He explained that their initial approach to facility design was fairly cautious. However, as they advanced in finalising the overall equipment operations, it became clear that they could enhance their production rate.

“We are currently in the final stages of the DFS, where we are meticulously reviewing all cost factors, including operating consumables and purchased items,” Tan noted.

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Altech Batteries announced that it has finalised the design of its 60KWh battery pack after extensive collaborations with component suppliers.

The ASX-listed company said the design has undergone significant improvements, now featuring a sleek stainless-steel exterior with the prominent CERENERGY logo on top and “ALTECH Batteries” engraved at the bottom.

One of the primary enhancements is the adoption of a stainless-steel casing that replaces the previous blue paint.

This new casing is designed to withstand extreme temperature variations, from snowy to desert conditions, all while maintaining its pristine appearance.

To ensure optimal insulation, the battery’s casing is equipped with a vacuum-sealed, double-sided enclosure.

Given the internal temperature of approximately 270 degrees Celsius, minimising heat transfer losses and ensuring human safety is of utmost importance.

The base of the battery has also been reinforced to accommodate high-temperature-resistant electrical cables and connectors, further reducing heat loss to the environment.

To address cold-starting issues, heating pads have been integrated into the vacuum-packed casing. The heating process typically takes around ten hours before the battery is fully activated.

Once initialised, the battery efficiently maintains its internal temperature with minimal reliance on the heating pads.

Additionally, improvements have been made to the internal frames, each housing 48 cells, to optimise their performance.

The connector plates, responsible for electrically linking the cells while maintaining insulation with mica insulation, have been meticulously designed. The cells themselves are connected through precise laser-targeted welding.

As previously announced, two working prototype ABS60 KWh batteries have been ordered from Fraunhofer Institute partners.

The production of these packs is already underway, with about half of the required cells already completed. While the production capacity is limited by the size of pilot plant equipment and kiln capacity at the Fraunhofer Institute, significant progress has been made.

Simultaneously, the first stainless-steel vacuum-sealed battery case has been delivered to the Fraunhofer Institute in Dresden.

Comprehensive heat transfer loss testing and temperature profiling will be conducted on the battery casing before assembling the battery cells. Once the cells are completed, they will be assembled into the pack for further cycling and long-term performance tests.

Group Managing Director Iggy Tan expressed his satisfaction with the battery’s optimisation and the progress of the prototypes.

“The vacuum-sealed casing will provide the perfect insulation and minimise any heat loss, which is the key benefit of our sodium chloride solid-state batteries,” he noted.

Tan continued, “The production of the prototype batteries is progressing well. The produced cells are performing well under bench performance testing and it will be great to see the whole 60KWh unit under performance load. This is the first time our partner Fraunhofer has made such a large battery unit”.

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Altech Batteries has collaborated with the Centre of International Climate and Environmental Research (CICERO) to demonstrate the environmental credentials of its CERENERGY battery project.

The ASX-listed company has enlisted the services of CICERO to conduct an external assessment of its environmental credentials, as revealed in an ASX announcement.

CICERO is renowned for its expertise in providing independent evaluations for green credentials, particularly within the green bond market. 

Previously, the company sought CICERO’s accreditation for its Silumina Anodes project, which received a “Light Green” rating.

Managing director Iggy Tan said, “There is clearly an environmental advantage of the CERENERGY battery and proposed factory.

He added, “Considering the GHG footprint evaluation conducted by independent groups, we anticipated from the outset that our batteries would be classified as ‘green batteries’. 

Tan also noted that the company is currently in the official accreditation process.

The move underscores the company’s emphasis on ecologically friendly energy storage options and its goal to lead the field in green battery technology.

To date, Altech is concentrating its efforts on the grid storage battery market, with its innovative Sodium-Chloride Solid State CERENERGY batteries.

Altech Batteries now hopes that by offering significant reductions in greenhouse gas emissions, the use of renewable energy, and an integrated recycling facility, it will demonstrate its commitment to transparency and sustainability, as well as appeal to socially and environmentally conscious investors.

A recent study conducted by the Sustainable Technologies Laboratory at Bochum University of Applied Sciences recently analysed the environmental impact of different battery types.

The findings showed that CERENERGY batteries, which use nickel and sodium chloride, have a greenhouse gas (GHG) footprint that is at least 50 per cent lower than that of lithium-ion batteries since they do not contain any of the key metals linked to high GHG emissions.

Altech’s commitment to sustainability extends to its planned CERENERGY battery project in Saxony, which will use renewable energy and feature on-site power generating through photovoltaic panels as well as energy storage capabilities.

The plant was designed to reduce its greenhouse gas emissions by utilising renewable energy for activities such as sintering ceramic tubes and avoiding the usage of natural gas entirely.

In addition, Altech has adopted a proactive approach to recycling by incorporating a recycling facility within the factory. 

This distinguishes the company from many lithium-ion battery manufacturers who rely on third-party recycling organisations.

The ASX-listed company said the recycling device will remove and recycle various battery components effectively, assuring correct disposal and reducing waste and environmental impact.

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Altech Batteries has begun production and fabrication of two 60 kilowatt hour (KWh) battery pack prototypes at the Fraunhofer IKTS facility in Hermsdorf, Germany.

Once completed, the ASX-listed company said the battery packs will undergo cycling testing under extreme conditions, before being made available for testing at customer locations.

The battery pack is intended for the grid storage and renewable energy industries and operates at a voltage of 600 volts and a current of 100 amps.

Altech and its joint venture partner Fraunhofer unveiled the concept for the CERENERGY sodium chloride solid state (SCSS) 60 KWh battery pack on 7 November 2022.

The joint venture conducted extensive cycling simulations after the launch to assess the temperature distribution of the battery’s interior components.

The calculations demonstrated that the battery could cycle through charges and discharges at recorded temperatures of 60 degrees while maintaining constant internal temperatures and avoiding overheating.

Iggy Tan, the managing director of Altech, said he was “pleased” with the business’s development since the battery pack debut.

“We have built a dynamic and fast-moving project team incorporating personnel from Altech, Fraunhofer and various leading German engineering companies and industrial contractors,” Tan noted.

The Altech official also pointed out that the rapid progress made on the final designs of the 60 KWh Battery Pack is remarkable.

According to the company, the specifications for the battery packs were being finalised based on the findings of the simulation, and the materials needed to produce two prototype batteries had been ordered.

Altech also revealed that the manufacturing of 480 ceramic solid-state cells will be done during the production process, along with the creation and acquisition of auxiliary tools such as cabling, module structures, composite isolation cabinets, and battery management systems.

The Altech-Fraunhofer joint venture is now commercialising a 100 MWh per annum SCSS battery plant designed exclusively for the stationary energy storage market and located on Altech’s Saxony, Germany, site.

In March 2023, the battery technology company launched the design for its 1.0 MWh GridPack (ABS1000) battery system.

The pre-installed solution includes up to 18 ABS60 60 KWh battery packs that are linked to a pack power management system.

The Altech GridPacks are also designed with a “plug and play” capability to allow for easy installation in remote places.

These GridPacks may be layered on top of one another, unlike other gigantic battery pack designs now on the market, according to the company.

In turn, the solution reduces the battery footprint and makes it simple to scale up to meet any energy storage needs.

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ASX-listed Altech Chemicals has established its own research and development laboratory in Perth, Western Australia.

The laboratory, which has been in a commissioning phase since May and is now close to finalisation, will enable Altech to conduct a full range of research, development and test work – including battery tests – to refine its graphite and silicon particle battery materials HPA coating technology, unhindered.

Previously this work was being conducted at Curtin University and needed to be scheduled around laboratory availability, which did not always fit with Altech’s requirements.

High purity alumina (HPA) is a high-value, high margin product which is increasingly used by lithium-ion battery manufacturers as the coating on the battery’s separator to improve performance, longevity and safety of the battery.

Altech said in a statement that it has received the first samples of battery materials which will be subjected to various rounds of development tests at the new laboratory.

“Another round of halfcell battery performance tests is also planned – to further test the performance of graphite and silicon particles that have been coated with alumina, using Altech’s proprietary technology,” reads the statement.

Altech is aiming to become one of the world’s leading suppliers of HPA through the construction and operation of a 4,500tpa processing plant at Johor, Malaysia.

Feedstock for the plant will be sourced from the company’s 100%-owned kaolin deposit at Meckering, Western Australia and shipped to Malaysia.

Image credit: Altech Chemicals Facebook page

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