Steeve Rousselot
Credit: Alejandra Guitron
Lithium iron phosphate (LiFePO₄, or LFP) batteries are rapidly replacing lithium-ion batteries in electric vehicles and other applications. Many people think they are the future of battery technology, but not many are aware of Université de Montréal's role in developing the LFP manufacturing process.
"Our contribution to phosphate chemistry for the battery industry hasn't got the recognition it deserves," said Steeve Rousselot, a researcher in the Laboratoire Chimie et Electrochimie des Solides supervised by chemistry professor Mickaël Dollé.
But the pioneers in the field are here, and so is the machine that led to the first patents for phosphate enhancement."
Michel Gauthier, a visiting researcher in the chemistry department and dean of UdeM's LFP pioneers, agrees: "UdeM's expertise is seriously underestimated," said Gauthier, who founded Phostech Lithium in 2001, sold it in 2008 and now is busy with a second start-up based on battery research at LCES, Ignis Lithium.
The company could prove particularly impactful, he believes. At a time when critical political and business decisions are being made around cleaner and more independent energy production, the patented synthesis technology developed by UdeM researchers shows strong potential, he said.
China in the lead
Currently, China accounts for over 95 per cent of global production of LFP for batteries. Yet "research at UdeM led to the patents for solid-state manufacturing of LFP and made its use in batteries possible," said Rousselot, who is also R&D director at Ignis Lithium.
Conducted in the early 2000s, that research led to the establishment of Phostech Lithium, UdeM's first start-up, and of industrial production of LFP for the first time anywhere in the world.
"We knew there was a future for LFP in batteries," Gauthier recalled. "At the time, the market was dominated by lithium-ion batteries made of cobalt and nickel-two expensive, rare and toxic elements-and their use was limited to portable electronics."
By contrast, iron is non-toxic and the manufacturing process produces no toxic emissions, he noted.
However, China took the lead by optimizing the processes developed at UdeM for energy storage, which is crucial for electric vehicles. Phostech Lithium and its Candiac plant shut down soon after the company lost its exclusive rights to the patents.
"We invented an economical process, which the Chinese adopted," said Gauthier. "That's why they're able to produce nearly two million tonnes per year today."
Inspired by steel and glass
Research at UdeM didn't stop after Phostech Lithium closed. The same research team went on to develop a groundbreaking melt synthesis process for LFP, drawing inspiration from the steel and glass industries.
"When the Chinese broke into the market with lithiated iron phosphate, we decided it was still worth working on this innovative new process, which would be more economical and have less environmental impact," said Gauthier.
"This process is so flexible that we can produce the material using Quebec minerals, at the same cost as the Chinese," Rousselot added.
Currently, lithium, iron and phosphate are all mined in Quebec-but processed on the other side of the world. "And then we buy it back, at a higher price," said Rousselot. "The idea is to change this model."
A diverse team
Development of the melt synthesis process led to the establishment of Ignis Lithium, a start-up with a diverse team of professors, researchers, engineers and lawyers that use UdeM's facilities.
"Instead of constructing a building, as is usually done, we opted to use existing resources within the network of laboratories that we were already familiar with," Gauthier explained. "As a result, we're able to do process development with a decentralized structure that costs relatively little."
Dollé's laboratory has been used for process R&D, while other technology transfer centres in Quebec and Ontario are supporting scale-up and the production of ultra-fine powder ready for use in batteries.
"The research contract with UdeM gives us access to research and characterization facilities that wouldn't otherwise be available to us," said Rousselot.
Their product has passed the battery assemblers' quality tests and Ignis Lithium is now seeking major partners to help it scale up production.
"It's all well and good to have technology and patents, but we need to bring our product to market quickly," Gauthier said. The team isn't content to rest on its laurels after discovering the new process; they want to apply it to fuel local development of a highly strategic industry, he added.
"When you have a good idea, you want it to be recognized."
