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Volume 104
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Simulation of an intensive lab mixer for dry mixing of Li-ion cathode materials via the discrete element method (Open Access)
Clemens Lischka *, Hermann Nirschl
Institute for Mechanical Process Engineering and Mechanics (MVM), Karlsruhe Institute of Technology, Straße am Forum 8, Karlsruhe, 76131, Germany
10.1016/j.partic.2025.06.002
Volume 104, September 2025, , Pages 52-67
Received 24 July 2024, Revised 15 May 2025, Accepted 3 June 2025, Available online 20 June 2025, Version of Record 26 June 2025.
E-mail: clemens.lischka2@kit.edu
Highlights

• A simulation model was successfully validated to describe dry mixing cathode materials in Eirich intensive mixers.

• Increased filling height, vessel speed, mixing tool size and design were found to improve dry mixing.

• While collision rates generally decrease with increasing mixing tool speeds, total collision energy increases.

• Degree of CB comminution can be described via the specific energy input and its effect on overall mixture bulk density.

• The mixing tool design can be optimized to reduce the process time and associated production cost during dry mixing.


Abstract
Graphical abstract
Keywords
Li-ion battery production; NMC-622; Carbon black; Dry mixing; Discrete element method; Simulation; Intensive mixer
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