Alpha HPA develops technology to make Li-ion batteries safer

Alpha HPA, an Australian manufacturer of ultrahigh-purity aluminium, has announced it is making major inroads into improving battery safety for EVs with proprietary technology that greatly reduces fire risk.

Recent news reports highlighting the rise in lithium-ion battery fires have sparked significant concern in Australia, and with the waste and recycling industry reporting that it is fighting up to 12,000 fires a year caused by discarded lithium-ion batteries, and also in the wake of several headline-grabbing electric vehicle (EV) fires around the world, urgent new safety standards are clearly needed.

Alpha HPA’s Managing Director Rimas Kairaitis said impressive advancements in EV technology were driving the world towards a lower-carbon future, aligning with Alpha’s commitment to supporting sustainable and secure energy.

“At its core, the lithium-ion battery operates on controlled oxidation reactions; however, under certain conditions, such as physical damage or the use of lower-quality materials, these reactions can escalate rapidly and uncontrollably, leading to thermal runaway, or battery fires,” he said.

To address these risks, Alpha HPA has developed a solution that builds upon a process originally pioneered by battery anode manufacturer BTR New Materials in the 2010s. This process, called the Ultra Coat, has demonstrated a remarkable 100% reduction in thermal runaway events, effectively enhancing the safety of lithium-ion batteries.

Alpha HPA has successfully filed a provisional patent for a process that utilises its proprietary ultrahigh-purity aluminium nitrate precursor to apply a controlled thickness of high-purity aluminium oxide and hydroxide coatings to various surfaces within the Li-ion battery cell environment.

This advancement represents a significant step forward in fire-reduction technology, aiming to make lithium-ion batteries safer for widespread use, the company said.

“With a commitment to innovation and safety, Alpha HPA is poised to support the broader adoption of lithium-ion battery technology and help pave the way for a sustainable, secure and safe energy future,” Kairaitis said.

The Ultra Coat technology is also versatile, with potential applications extending to other e-mobility products, household batteries and grid energy storage, further contributing to enhanced safety in other applications.

“As the world intensifies efforts to combat climate change and reduce energy consumption, the need for reliable and safe energy storage solutions has never been greater,” Kairaitis said. “Alpha HPA’s groundbreaking Ultra Coat Process not only addresses a critical safety concern but also aligns with global sustainability goals, ensuring the continued development of clean energy technologies.”

Alpha HPA says its technology results in up to 70% lower total carbon emissions in comparison to traditional, emissions-intensive methods of HPA production. It achieves this by using a common industrial chemical feedstock, by recycling 100% of key reagents as by-products, and by using 100% renewable energy to power its operations.

Image courtesy of Alpha HPA.