Battery technologies The world's largest factory for lithium-sulfur batteries is being built in Nevada

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Lyten, a company specializing in lithium-sulfur batteries, is set to construct the world's first gigafactory dedicated to this type of battery near Reno, Nevada (USA). With an ambitious goal of producing up to 10 GWh annually, this facility aims to be a significant player in the next-generation battery market. The project, estimated at a cost of $1 billion, is scheduled to begin operations by 2027. This strategic move could enhance the scalability and availability of lithium-sulfur batteries, which offer potential advantages over traditional lithium-ion technologies, including higher energy density and improved sustainability.

Lyten is building the world's largest lithium-sulfur battery gigafactory with an investment of $1 billion US dollars. The facility will produce not only active cathode materials and lithium metal anodes but will also handle the complete assembly of lithium-sulfur battery cells. The production of solid-state batteries in both cylindrical and pouch formats is planned.

The company Lyten was founded in 2015 and describes itself as a "company for the application of super materials." A focus is on the relatively new branch for the mass production of high-performance lithium-sulfur batteries: In 2023, the company started a semi-automated pilot facility in San Jose, California, for battery production. Batteries produced there are supposed to be used in markets such as drone manufacturing, aerospace, micromobility, and the defense industry throughout the remaining year of 2024 and over the course of 2025.

Lithium-sulfur batteries: Ready for the mass market?

Lyten expects that the time has come for lithium-sulfur batteries to make a significant appearance in the mass market. The construction of the Gigafactory in Nevada is prompted by the expectation of a strong increase in demand for this battery technology. The planned facility is to occupy a total area of 1.25 million square meters and initially employ 200 staff upon starting the first production phase in 2027. Lyten anticipates that by the time of full operation at full capacity, over 1,000 employees will work there, including researchers and developers, manufacturing engineers, battery engineers, technicians, and machine operators.

"Today marks the latest milestone in Lyten's nine-year history," said Dan Cook, co-founder and CEO of Lyten, during the announcement. "Lithium-sulfur represents a leap in battery technology, enabling a high-energy density and lightweight battery made from abundantly available local materials and manufactured 100% in the USA." Lyten is planning a sustainable battery production that is carried out completely in the USA, from component manufacturing to final assembly.

Lithium-sulfur batteries have been considered potential successors to the widely used lithium-ion batteries for several years. According to research findings, solid-state batteries based on sulfides have, depending on their composition, about three to five times the capacity of their commercially established counterparts. This greater energy density allows for a significantly more compact and lightweight construction: According to Lyten, the batteries produced in California and, in the future, in Nevada are expected to be up to 40% lighter than equivalent lithium-ion batteries and up to 60% lighter than the also considered alternative technology of Lithium iron phosphate batteries, also known as LFP batteries. Another advantage is that these batteries do not require rare and critical elements like cobalt or nickel. By utilizing readily available sulfur as the active cathode material, these batteries can be produced more sustainably and cost-effectively.

Sulfur, however, is a poorer electrical conductor. Additionally, in combination with the highly reactive material lithium, there is a faster decay of the resulting battery cells. The result is a quicker decline in possible charging cycles and storage capacity, thus a shorter overall lifespan compared to conventional lithium-ion batteries. This has so far limited the economic viability of the technology, making it unattractive for the market for a long time. Numerous research breakthroughs in recent years, such as new approaches in cathode production and advances in the design of battery cells, have significantly minimized these disadvantages.

Lyten is collaborating with local authorities and companies and plans the groundbreaking for the planned Gigafactory for spring 2025. The entire production supply chain for the lithium-sulfur batteries is to be located in the USA. Thus, Lyten promises that the batteries produced there will not be subject to any trade restrictions, such as those from the ongoing trade dispute between the USA and China.(sg)