Grant: Alliance Grants

Nano high purity alumina or nano-HPA (i.e., purity more than 99.99% with nanoparticles) is in high demand for use in lithium-ion batteries where it is used as a coating material on anodes, cathodes or ceramic separator sheets between the the anode and the cathode. As another application, it has a lower sintering temperature (1300 °C vs 1800 °C) allowing energy savings in the bio-ceramics manufacturing industry. Nano HPA whose dimensions are less than 100 nm is a high-end product on the market. In fact, the Japanese producer, Taimei Chemicals Co, is the only producer of nano-alumina with particles below 100 nm, where the product is sold at a price 10 times higher than standard HPA that has micron-sized powders. The primary objective of this research is to develop a scalable and sustainable process for producing nano-HPA using a cost-effective precursor, which is produced from Canadian aluminous clays. Three alternative processes will be investigated, and their commercialization potential will be analyzed by iterative process scale-up approach. The anticipated outcomes include highly qualified personnel (via training of 4 postdocs, 1 master's student and 3 bachelor's students) for the production of premium nano HPA with a high surface area and size distribution less than 100 nm, ensuring minimal agglomeration. The results will be disseminated through at least 2 patents and 8 peer-reviewed publications, contributing to the academic and industrial knowledge base. Additionally, it will enhance the competitiveness of Canadian industries by providing a domestic source of nano-HPA, supporting the development of high-performance materials for energy storage, electronics, and ceramics, and contributing to environmental sustainability through cleaner production methods.