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A Two-Pot Furnace Approach to Silicon Nanoparticle Graphite Composite Anodes for Lithium-Ion Batteries
Mid Sweden University, Faculty of Science, Technology and Media, Department of Engineering, Mathematics, and Science Education (2023-).ORCID iD: 0000-0002-7324-9400
2026 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Lithium-ion batteries are crucial for the transition to a sustainable energy society, powering everything from portable electronics to electric vehicles. To meet the ever-growing demand for higher energy density, silicon has emerged as one of the most promising alternative anode materials due to its exceptionally high theoretical capacity (up to 4200 mAhg⁻¹), which is nearly ten times that of conventional graphite anode. However, the massive volume expansion (~300–400%) of silicon during lithiation causes severe mechanical stress, particle pulverization, and rapid capacity fading, limiting its commercial viability. This thesis aims to develop safe, low-cost, and scalable silicon-based anode materials by engineering nanostructured silicon graphite composites and elucidating their fundamental growth mechanisms. This was achieved through a stepwise progression, beginning with a one-pot thermal synthesis of a highly stable silicon-nanographite aerogel (SNGA) composite, and advancing to a two-pot furnace method that decouples precursor generation from nanoparticle deposition. Morphological analysis revealed the in-situ growth of silicon nanoparticles directly onto nanographite flakes, effectively buffering volume expansion during cycling. To better understand and control this nanoparticle formation, a two-pot furnace method was developed, successfully decoupling precursor generation from nanoparticle deposition. This hydrogen-assisted approach eliminates the need for highly toxic precursor gases typical of Chemical Vapor Deposition (CVD). By systematically investigating the thermodynamic and kinetic parameters, including temperature, gas flow rate, and dwell time the underlying growth mechanism was identified. Electrochemical evaluation of the resulting binder-free composite electrodes via cyclic voltammetry and galvanostatic charge-discharge cycling confirmed their structural integrity and electrochemical stability. The findings presented in this thesis offer a viable pathway for the production of silicon nanoparticle based high-capacity lithium-ion battery anodes.

Abstract [sv]

Litiumjonbatterier är avgörande för omställningen till ett hållbart energisamhälle och driver allt från bärbar elektronik till elfordon. För att möta den ständigt växande efterfrågan på högre energidensitet har kisel framträtt som ett av de mest lovande alternativa anodmaterialen på grund av dess exceptionellt höga teoretiska kapacitet (upp till 4200 mAh g⁻¹), vilket är nästan tio gånger högre än för konventionella grafitanoder. Emellertid orsakar den massiva volymexpansionen (~300–400%) hos kisel under litiering allvarliga mekaniska spänningar, partikelsönderdelning och snabb kapacitetsförlust, vilket begränsar dess kommersiella gångbarhet. Denna avhandling syftar till att utveckla säkra, kostnadseffektiva och skalbara kiselbaserade anodmaterial genom att konstruera nanostrukturerade kisel-grafitkompositer och klargöra deras grundläggande tillväxtmekanismer. Arbetet har fortskridit stegvis, med utgångspunkt i en termisk en-kärlssyntes (one-pot) av en mycket stabil kisel nanografit aerogelkomposit (SNGA). Morfologisk analys påvisade in situ-tillväxt av kiselnanopartiklar direkt på nanografitflak, vilket effektivt dämpar volymexpansionen under cykling. För att bättre förstå och kontrollera denna nanopartikel bildning utvecklades en två-kärls ugnsmetod (two-pot), som framgångsrikt separerade genereringen av prekursorer från deponeringen av nanopartiklar. Detta vätgasassisterade tillvägagångssätt eliminerar behovet av mycket giftiga prekursorgaser som annars är typiska för kemisk ångdeponering. Genom att systematiskt undersöka termodynamiska och kinetiska parametrar, inklusive temperatur, gasflödeshastighet och uppehållstid, kunde den bakomliggande tillväxtmekanismen identifieras. Elektrokemisk utvärdering av de resulterande bindemedelsfria kompositelektroderna och urladdningscykling bekräftade deras strukturella integritet och elektrokemiska stabilitet. De resultat som presenteras i denna avhandling erbjuder en framkomlig väg för produktion av högkapacitetsanoder för litiumjonbatterier baserade på kiselnanopartiklar.

Place, publisher, year, edition, pages
Sundsvall: Mid Sweden University , 2026. , p. 72
Series
Mid Sweden University doctoral thesis, ISSN 1652-893X ; 457
National Category
Composite Science and Engineering
Identifiers
URN: urn:nbn:se:miun:diva-57388ISBN: 978-91-90017-86-9 (print)OAI: oai:DiVA.org:miun-57388DiVA, id: diva2:2061416
Public defence
2026-06-12, O111, Holmgatan 10, Sundsvall, 08:00 (English)
Opponent
Supervisors
Note

Vid tidpunkten för disputationen var följande delarbete opublicerat: delarbete 6 manuskript.

At the time of the doctoral defence the following paper was unpublished: paper 6 in manuscript.

Available from: 2026-05-21 Created: 2026-05-21 Last updated: 2026-05-21Bibliographically approved
List of papers
1. Silicon-Nanographite Aerogel-Based Anodes for High Performance Lithium Ion Batteries
Open this publication in new window or tab >>Silicon-Nanographite Aerogel-Based Anodes for High Performance Lithium Ion Batteries
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2019 (English)In: Scientific Reports, E-ISSN 2045-2322, Vol. 9, article id 14621Article in journal (Refereed) Published
Abstract [en]

To increase the energy storage density of lithium-ion batteries, silicon anodes have been explored due to their high capacity. One of the main challenges for silicon anodes are large volume variations during the lithiation processes. Recently, several high-performance schemes have been demonstrated with increased life cycles utilizing nanomaterials such as nanoparticles, nanowires, and thin films. However, a method that allows the large-scale production of silicon anodes remains to be demonstrated. Herein, we address this question by suggesting new scalable nanomaterial-based anodes. Si nanoparticles were grown on nanographite flakes by aerogel fabrication route from Si powder and nanographite mixture using polyvinyl alcohol (PVA). This silicon-nanographite aerogel electrode has stable specific capacity even at high current rates and exhibit good cyclic stability. The specific capacity is 455 mAh g−1 for 200th cycles with a coulombic efficiency of 97% at a current density 100 mA g−1.

Keywords
Silicon-Nanographite Aerogel-Based Anodes for High Performance Lithium Ion Batteries Supplementary Information
National Category
Condensed Matter Physics
Identifiers
urn:nbn:se:miun:diva-37569 (URN)10.1038/s41598-019-51087-y (DOI)000489555900015 ()2-s2.0-85073112106 (Scopus ID)
Available from: 2019-10-24 Created: 2019-10-24 Last updated: 2026-05-21Bibliographically approved
2. Highly Stable Cycling of Silicon-Nanographite Aerogel-Based Anode for Lithium-Ion Batteries
Open this publication in new window or tab >>Highly Stable Cycling of Silicon-Nanographite Aerogel-Based Anode for Lithium-Ion Batteries
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2021 (English)In: ACS Omega, E-ISSN 2470-1343, Vol. 6, no 10, p. 6600-6606Article in journal (Refereed) Published
Abstract [en]

Silicon anodes are considered as promising electrode materials for next-generation high-capacity lithium-ion batteries (LIBs). However, the capacity fading due to the large volume changes (∼300%) of silicon particles during the charge−discharge cycles is still a bottleneck. The volume changes of silicon lead to a fracture of the silicon particles, resulting in the recurrent formation of a solid electrolyte interface (SEI) layer, leading to poor capacity retention and short cycle life. Nanometer-scaled silicon particles are the favorable anode material to reduce some of the problems related to the volume changes, but problems related to SEI layer formation still need to be addressed. Herein, we address these issues by developing a composite anode material comprising silicon nanoparticles and nano graphite. The method developed is simple, cost-efficient, and based on an aerogel process. The electrodes produced by this aerogel fabrication route formed a stable SEI layer and showed high specific capacity and improved cyclability even at high current rates. The capacity retentions were 92 and 72% of the initial specific capacity at the 171st and the 500th cycle, respectively.

Keywords
Lithium Ion Batteries, Silicon, Graphene, Nanographite, Aerogel
National Category
Natural Sciences Materials Chemistry
Identifiers
urn:nbn:se:miun:diva-41304 (URN)10.1021/acsomega.0c05214 (DOI)000631101200010 ()2-s2.0-85103375502 (Scopus ID)
Funder
Swedish Energy AgencyThe Swedish Foundation for International Cooperation in Research and Higher Education (STINT), IB2020-8645VinnovaEU Sixth Framework Programme for ResearchKnowledge Foundation
Available from: 2021-03-02 Created: 2021-03-02 Last updated: 2026-05-21Bibliographically approved
3. Exploring silicon nanoparticles and nanographite-based anodes for lithium-ion batteries
Open this publication in new window or tab >>Exploring silicon nanoparticles and nanographite-based anodes for lithium-ion batteries
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2024 (English)In: Journal of materials science. Materials in electronics, ISSN 0957-4522, E-ISSN 1573-482X, Vol. 35, no 21, article id 1465Article in journal (Refereed) Published
Abstract [en]

This study investigates the performance of silicon nanoparticles (Si NPs) and silicon nanographite (SiNG) composite-based anodes for lithium-ion batteries (LiBs). Si offers a promising alternative to traditional graphite anodes due to its higher theoretical capacity, despite encountering challenges such as volume expansion, pulverization, and the formation of a solid electrolyte interface (SEI) during lithiation. SiNPs anode exhibited initial specific capacities of 1568.9 mAh/g, decreasing to 1137.6 mAh/g after 100th cycles, with stable Li–Si alloy phases and high Coulombic efficiency (100.48%). It also showed good rate capability, retaining 1191.3 mAh/g at 8400 mA g−1 (2.82C), attributed to its carbon matrix structure. EIS indicated charge transfer with RB of 3.9 Ω/cm−2 and RCT of 11.4 Ω/cm−2. Contrastingly, SiNG composite anode had an initial capacity of 1780.7 mAh/g, decreasing to 1297.5 mAh/g after 100 cycles. Its composite structure provided cycling stability, with relatively stable capacities after 50 cycles. It exhibited good rate capability (1191.3 mAh/g at 8399.9 mA g−1), attributed to its carbon matrix structure. Electrochemical impedance spectroscopy showed higher resistances for RB of 4.2 Ω/cm−2 and RCT of 15.6 Ω/cm−2 compared to SiNPs anode. These findings suggest avenues for improving energy storage devices by selecting and designing suitable anode materials.

Place, publisher, year, edition, pages
Springer Nature, 2024
National Category
Materials Chemistry
Identifiers
urn:nbn:se:miun:diva-52005 (URN)10.1007/s10854-024-13140-z (DOI)001277699700004 ()2-s2.0-85199420697 (Scopus ID)
Funder
Swedish Energy Agency, 39038-2The Swedish Foundation for International Cooperation in Research and Higher Education (STINT), IB-2018 7535Mid Sweden University
Available from: 2024-07-26 Created: 2024-07-26 Last updated: 2026-05-21
4. Engineering Silicon Nanoparticle Anodes by Decoupling Precursor Generation and Deposition via a Two‐Pot Furnace Method
Open this publication in new window or tab >>Engineering Silicon Nanoparticle Anodes by Decoupling Precursor Generation and Deposition via a Two‐Pot Furnace Method
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2025 (English)In: Nano Select, ISSN 2688-4011, Vol. 6, no 12, article id e70033Article in journal (Refereed) Published
Abstract [en]

Silicon materials are currently being explored for usage in lithium–ion battery anodes due to their high lithium storage capacity,but their practical application is hindered by severe volume expansion during cycling, leading to mechanical degradation andcapacity fading. This study introduces a novel two-pot method for synthesizing silicon nanoparticles (Si NPs) to address thesechallenges. The method decouples precursor decomposition and nanoparticles deposition enabling in situ growth of Si NPs onnanographite substrates. By replacing hazardous silane precursors with polyvinyl alcohol or hydrogen gas, we eliminate safetyrisks while simplifying production. Scanning electron microscopy and electrochemical characterization confirm uniform Si NPdeposition. The fabricated electrodes displayed stable electrochemical performance with a capacity of 503 mAh/g after 100 cyclesin a half-cell configuration. This approach offers a safe route for producing high-performance silicon-based anodes.

Place, publisher, year, edition, pages
Wiley, 2025
Keywords
Silicon nanoparticles, Lithium-ion batteries, Thermal synthesis, Scalable manufacturing, Anode materials.
National Category
Nanotechnology for Energy Applications
Identifiers
urn:nbn:se:miun:diva-54734 (URN)10.1002/nano.70033 (DOI)001513526300001 ()
Funder
Swedish Energy Agency, 2021‐002255The Swedish Foundation for International Cooperation in Research and Higher Education (STINT), IB‐2022 9234Vinnova, 2020-00798European Regional Development Fund (ERDF)
Available from: 2025-06-24 Created: 2025-06-24 Last updated: 2026-05-21Bibliographically approved
5. Low-Cost Furnace-Grown Silicon Nanoparticles on Nanographite: A New Pathway to Produce LIB Anodes
Open this publication in new window or tab >>Low-Cost Furnace-Grown Silicon Nanoparticles on Nanographite: A New Pathway to Produce LIB Anodes
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2025 (English)In: Materials Science Forum, ISSN 0255-5476, E-ISSN 1662-9752, Vol. 1168, p. 79-84Article in journal (Refereed) Published
Abstract [en]

Silicon materials are currently being explored for usage in lithium-ion battery anodes due to their high lithium storage capacity. We have developed a novel method, using a simple thermal treatment of low-cost silicon powder and nanographite, resulting in a composite where silicon nanoparticles are grown on the graphene surfaces. Electrodes fabricated from these Si-NG composites delivered a stable capacity of 489 mAh/g during 25 cycles, i.e. higher than conventional graphite anodes (theoretical capacity: 372 mAh/g). The method uses low-cost materials and avoids complex setups, thereby suggesting industrial scalability.

Place, publisher, year, edition, pages
Trans Tech Publications Inc., 2025
National Category
Condensed Matter Physics
Identifiers
urn:nbn:se:miun:diva-56245 (URN)10.4028/p-mqo1m7 (DOI)2-s2.0-105025704327 (Scopus ID)
Available from: 2025-12-10 Created: 2025-12-10 Last updated: 2026-05-21Bibliographically approved

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Patil, Rohan

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