Optimization of Graphite Spheronization Using a Digital Twin
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At its graphite processing facility, Nouveau Monde Graphite (NMG) employs a gas-based spheronization process to precisely control the particle size distribution (PSD) of graphite. Graphite, an allotrope of carbon, plays a critical role in several industrial applications, including lithium-ion batteries, lubricants, refractories, and electronic devices. Among these, battery manufacturing imposes particularly stringent requirements on graphite PSD, as it significantly influences the material’s physical, chemical, and electrochemical properties.
In the context of lithium-ion batteries, smaller and more uniformly sized graphite particles enable higher electrode packing densities, leading to enhanced energy density and overall battery performance. However, due to the narrow PSD specifications demanded by battery manufacturers—often within a standard deviation as low as 5 µm—a substantial portion of the processed graphite falls outside acceptable limits and is therefore not commercially viable.
Consequently, the yield and operational efficiency of the spheronization units are critical factors influencing the overall process performance and the economic viability of the graphite refinement workflow. The gas-based spheronizer utilized by NMG involves several adjustable operating parameters, including gas flow rate, rotational speed of mechanical components, and feedstock characteristics (e.g., initial PSD, graphite source).
The primary objective of this project is to develop a digital twin of the spheronization process. This virtual model will be designed to simulate, predict, and optimize process behavior in real time, thereby enabling maximization of both yield and process robustness. Preliminary assessments suggest that optimized operating conditions, identified through the digital twin, could potentially double the spheronizer yield and reduce operational time and associated unit costs by up to 50%.
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