Novonix unveils results of Hatch’s engineering study on proprietary zero-waste cathode synthesis process

Image credit: Novonix

Novonix, an ASX-listed manufacturer of battery materials and technology, has announced the results of the Hatch engineering report on its proprietary cathode synthesis process. 

Global engineering consultancy firm Hatch was commissioned to conduct a comparison study and high-level evaluation of plant emissions and impacts on natural resources between Novonix’s patent-pending process and the conventional wet process. 

Novonix’s all-dry, zero-waste cathode synthesis process uses dry particle microgranulation, which requires fewer steps than the conventional process, without producing sodium sulphate, reducing facility cooling water by an estimated 65 per cent and eliminating the water needed for core materials processing. 

Hatch’s study found that Novonix’s patent-pending process could potentially reduce power consumption by an estimated 25 per cent and eliminate waste byproduct generation over the conventional process. 

These factors could allow a potential processing cost reduction of about 50 per cent and lower capital costs by approximately 30 per cent. 

The study estimated that Novonix’s process could consume fewer natural resources, likely requiring essentially no reagents and generating fewer waste streams. As a result, the Novonix process is likely more environmentally friendly and sustainable than the conventional process. 

“Hatch’s study supports our expected outcomes of our all-dry, zero-waste cathode synthesis process, which shows the potential for significant cost reductions and environmental benefits”, said Chris Burns, CEO of Novonix. 

“The cathode active materials market is projected to be greater than $100 billion in 2030 and the opportunity to deploy this new process to the battery industry is significant. Importantly, NOVONIX’s process is aligned with our mission of providing revolutionary clean energy solutions to the battery industry and further extends our competitive strengths in battery materials. Several potential customers and partners have already shown significant interest and this study validates the operating and capital cost savings achievable with our novel cathode synthesis process.”

In July 2023, Novonix began commissioning its 10-tonne per annum cathode pilot line. 

The company shared that its cathode material matches the performance of leading cathode materials from existing suppliers in full-cell testing. 

In an ASX announcement issued today, the company said it plans to continue to strengthen its intellectual property portfolio and further demonstrate the manufacturability of its long-life cathode materials and technology, including high-nickel and cobalt-free materials and technology.