The role of Metso’s PSI 1000® analyzer: Increasing efficiency, cost-savings, safety & sustainability

The global transition toward sustainable energy solutions has significantly impacted industries worldwide, particularly the transportation sector. The shift from fossil-fuel-powered vehicles to electric vehicles is driving demand for advanced battery technologies. Projections indicate that the market for battery cells will grow by over 20% annually until 2030, reaching an estimated global value of $360 billion. At the heart of this transformation lies the lithium-ion battery (LiB), a versatile and efficient energy storage solution used not only in electric vehicles but also in portable electronics and renewable energy systems.

A critical step in battery manufacturing is the production of precursor cathode active material (pCAM), which serves as the foundation for the battery electrode. The quality of pCAM – particularly particle size and uniformity - plays a key role in determining battery performance, charging properties and battery lifecycle.

“The battery precursor defines the performance of the battery, as the cathode active material inherits its properties from its precursors,” says Riikka Lepistö, Metallurgist at Metso. “Particle size and distribution in pCAM production are critical factors influencing the battery’s energy density and overall performance. Real-time monitoring of these parameters is essential to producing the best battery-grade precursor and, by extension, high-performance cathode materials.”

To address the challenges, Metso has developed an advanced online particle size analyzer for pCAM production process control in both hydrometallurgical and chemical processing applications: PSI® 1000 particle size analyzer.

By integrating the PSI® 1000 analyzer, operators can achieve precise control over particle size during the precipitation process. This eliminates inefficiencies, such as delays associated with traditional laboratory analysis. With the advantage of having immediate feedback and process adjustments, this in turn increases yield, cost-savings, safety; while minimizing the environmental footprint such as chemical reagents and water usage.

Advanced solution for real-time precision

The PSI® 1000 particle size analyzer has been designed to monitor particle size distribution in precipitation processes with unparalleled precision. Utilizing laser diffraction technology, the analyzer measures slurry particle sizes ranging from 0.1 µm to 100 µm, whilst providing comprehensive insights.

“It’s fine-tuned for a narrow size range, focusing on particles below 20 microns, with some even smaller than just a few microns,” says Lauri Mäenpää, Specialist, Hydromet Equipment at Metso. “We are  talking about a very narrow distribution located in the very fine spectrum of the particle size scale. Such precision is crucial in ensuring optimal packing density and performance of the final battery materials.”

The PSI® 1000’s ability to analyze particle size evolution in real-time enables operators to fine-tune reactions and maintain optimal conditions throughout the production process. In batch or semi-batch operations, the analyzer detects changes, allowing for proactive adjustments to prevent off-spec material. For continuous precipitation processes, the process control system leverages PSI® 1000 data to adjust reagents based on the measured particle size trends, thus preventing the process from fluctuating outside of its operational window to maintain process stability.

“The efficiency of the pCAM process will increase through the use of Metso online analyzers,” says Markus Koponen, Technology Manager, Precursors at Metso. “It’s important to have reliable online measurements for just the particles, so you can see that the process is in spec at all times.”

From hours to minutes: Eliminating delays and variability in pCAM production

One of the primary challenges in pCAM production is the reliance on traditional manual sampling and laboratory analysis methods. These approaches are often slow, costly and prone to variability, resulting in inefficiencies and delays in obtaining results. These inefficiencies can lead to an increased production of off-spec materials, as well as additional operational costs and downtime.

The PSI® 1000 overcomes these challenges by delivering near-instantaneous results, cutting analysis time from multiple hours to mere minutes.

“With this, operators receive results within six minutes or less, so they can make immediate adjustments,” says Koponen. “This rapid feedback loop provides a lot of data, and significantly reduces the amount of off-spec material in the long term.”

Achieving higher yields and lower costs

As previously stated, with automated process control, operators can respond swiftly to changes in metallurgical behavior. This, in turn, increases production rates and minimizes downtime. In addition to these benefits, off-spec products – which must be dissolved and reprocessed – are significantly reduced, leading to higher yields and lower operational expenses.

“The return on investment for the PSI® 1000 is quick,” says Koponen. “Once installed, the savings from reduced lab work, increased yield and decreased downtime quickly outweigh the initial costs – and the analyzer can be seen as practically free.”

The analyzer is also capable of monitoring up to ten sampling lines when production is scaled up, further demonstrating its cost-effectiveness. With the ability to monitor and control crucial parameters, product quality can remain consistent, and operators can achieve new levels of efficiency and reliability.

“The device also offers remote monitoring and access capabilities,” says Mäenpää. “This was immensely helpful in Pori operations in Finland, since the experts from another location, Espoo (Finland), had remote access and could help us when any problems or suspicious results arose.”

This, combined with minimizing the need for laboratory analysis and manual sampling, ensures the PSI® 1000 not only reduces operational costs but also improves sampling accuracy, thus providing comprehensive monitoring.

Safety, sustainability and seamless integration

An extra benefit of the PSI® 1000’s automated operation is that it not only improves efficiency, but also enhances workplace safety. Traditional sampling methods often expose operators to hazardous chemicals, such as ammonia vapors and high-pH slurries. By automating the sampling process, the PSI® 1000 eliminates these risks, creating a safer working environment.

“Since it's an automated system, it takes out the human factor there, so it is not dependent on an operator’s skill or habits,” says Mäenpää. “The machine is going to do the same thing repeatedly, in the same way, every time. This reduces systematic errors, helps in troubleshooting and allows operators to focus on the results of the measurements.”

Additionally, the analyzer’s minimal environmental footprint aligns with Metso’s sustainability goals. It requires no chemical reagents for operation and consumes only water, pressurized air and electricity. The resulting effluent is easily managed, further reducing environmental impact.

Integration with Metso’s digital solutions, including Geminex® digital twin and Metso Metrics services, enables seamless process optimization and performance monitoring. Metso’s global service network guarantees availability of spare parts and technical support, locally and remotely, over the lifecycle of the asset.

The PSI1000 can also integrate with an operation's own control system and features a local display, allowing operators to conveniently monitor results on-site. They can monitor the status of precipitation as well as the development of the particle size distribution – all from the PSI® 1000 analyzer screen or control system interface.

These advanced tools contribute to sustainable operations by improving resource efficiency and reducing waste.

Durability meets self-cleaning automation for simplified maintenance

With the ability to last decades without any major service packages, the PSI 1000 is very durable and long-lasting. Alongside robustness and reliability, the system has minimized the need for frequent manual intervention – demonstrated by its convenient self-cleaning mechanism.

Between each sample, the system automatically flushes itself, maintaining cleanliness to ensure consistent performance and avoiding cross-contamination with samples. While periodic cleaning of the analyzer’s optical sensor head may be required, this does not need to interrupt production, as cleaning of the analyzer can be performed between production cycles.

“It takes quite a while for buildup to occur, which simplifies operation,” says Lepistö. “It keeps itself clean, produces repeatable, reliable results, and guarantees that necessary tasks are automatically managed.”

For batch or semi-batch processes, the PSI 1000 takes on a monitoring role, tracking growth rates and initiating automated processes once the target median particle size (D50) value is reached. In a continuous mode, the PSI 1000 ensures that the D50 value remains consistently on target, as its integration with Metso's pCAM control system uses real-time parameter adjustments based on the PSI 1000's analysis.

“This means tasks such as emptying the reactor, draining the thickener or cleaning the system, these can all be automated,” says Koponen. “No operators need to push the buttons or remember to clean or rinse. With an increased automation level, operators can focus on other tasks while increasing efficiency.”

Driving sustainable and efficient battery minerals innovation

Ensuring precise particle size distribution is crucial, since it determines the packing density and energy density of the battery. In regard to the usage for electric vehicles, this ultimately affects the electric vehicle's range and acceleration capabilities.

By offering real-time monitoring of particle size distribution, the PSI 1000 allows for precise control and optimization of pCAM production processes. Thus, critical parameters of battery materials are consistently met, contributing to a cost-effective, sustainable and efficient production.

Metso’s PSI® 1000 particle size analyzer represents a transformative advancement in battery material production. Reliable automated insights and enhanced process efficiency gives the PSI® 1000 the ability to help operations meet the growing demand for high-quality battery materials.

In today’s world, digital solutions are keeping operations running safely and efficiently. Through innovative technologies and enhanced safety and sustainability, Metso is committed to shaping the future of battery production. That’s why, together, we are the partner for positive change.