Regenco, LLC - 75 Linwood Street, Bergenfield, NJ - 1(845) 535-1422
Regenco
RESEARCH & DEVELOPMENT
With Regenco's innovative research and manufacturing techniques, we plan to produce the most efficient Anode component of the NIB with enhanced conductivity, high cycling and voltage stability, comparable energy density and high capacity retention.
Research into Hard Activated Carbon Anode (HACA) has ramped up in the past few years, spurred by the battery and super capacitor industries and several advances in polymer science. Currently, lithium-ion batteries (LIB) is the popular choice, but recently, advances in sodium-ion batteries (NIB) technology has allowed NIB to close the gap in the market.
NIB is cheaper to manufacture - sodium is a renewable resource.
NIB performs better in cold weather (90% capacity at -20 Celsius), whereas LIB has poor performance.
It is safer and cheaper to ship SIB batteries (not considered a hazardous material).
Lithium is a known carcinogen and mining/processing this material is environmentally risky.
LIB is a known explosion/fire hazard due to thermal runaway, whereas NIB chemistry means a significantly lower risk of thermal runaway when subjected to overcharging, external heating, puncturing and other electrical abuse.
Energy density: 100-200 Wh/kg (SIB) versus 150-350 Wh/kg (LIB). Newer NIB designs closely bridge this gap and are almost comparable now to LIB. This means that to generate 100 KWh, SIB are now closer in weight and size of LIB.
Cycle life: up to 8,000 cycles of charge/discharge for LIB, versus ~6000 cycles for NIB.
Self-discharge: LIB typically has a lower discharge rate, about 2% to 3% (room temperature) versus SIB. However, dual salt technology in NIB research has proven to match the self-discharge rate of current LIB.
There is no cell damage when NIB discharges to 0V, LIB is permanently damaged if completely depleted.
NIB are proven to be the safer alternative to LIB; the fact that Sodium is more naturally abundant than Lithium, NIB has several obvious advantages.
Electrolyte chemistry, cathode structural design and HACA design can be developed imrpove NIB.
Specifically, HACA derived from coconut shells (CHACA) have been the main focus of research as the more flexible, effective and cheaper anode material compared to other options (carbon nanotubes, graphene, non-coconut based HACA).
Pore size and distribution can be controlled within CHACA to optimize ion transport and reduce volume expansion during cycling, leading to better cycling stability. Studies have shown that the optimal ratio of mesopore to micropore surface area (Smeso/Smicro) of 2.16 and mesopore to micropore volume (Vmeso/Vmicro) of 5.50 was associated with high specific capacitance, better rate performance, and improved cycling stability.
Doping CHACA with heteroatoms can also improve the performance of this anode. To improve cycling rate and charging, pyridinic and pyrrolic Nitrogen (N) is bound in CHACA, creating active storage sites that binds Na+ ions via surface-controlled pseudocapacitance. Sulfur (S) creates bonds with Carbon, boosting initial coulombic efficiency (ICE) and long -term cycling stability.
The following research and development will be undertaken by Regenco:
Successfully prepare Coconut Shells for efficient carbonization, where there is no waste and the charcoal mass is preserved.
Maximize Pore Hierarchy by developing a repeatable, consistent Activation Program to develop the ideal architecture for a sodium-ion anode.
Improve the performance of the CHACA by post-treatment co-doping with different elements like Nitrogen, Sulfur, Boron and/or Phosphorus.
Engineer the Activation and Doping Program for industrial scale processing of larger batch to fulfill Market Demand.
The coconut shell is removed of its meat. It will be dried, crushed, and sent to our biochar oven in batches, to carbonize the shells in the absence of oxygen.
Our 2-ton Carbonization Oven recirculates the gas byproducts as fuel that feeds the furnace. The majority of the smoke and vapors are condensed in twin cooling stacks, where Pyroligneous Acid (Wood Vinegar), Tar and Volatiles are collected. The carbonized coconut shells will subsequently be cooled, sieved to segregate the different granular sizes. We have standard sizes for specific applications in our STORE.
The released compounds and other byproducts are condensed and collected in the smoke condensing stacks to be aged and refined into agricultural Wood Vinegar.
Each batch will be tested for gradation, specific gravity and ash content before proceeding to the next stage.
We activate coconut biochar in a programmable split-tube furnace using steam (H2O) in proprietary dosages and duration.
A oil bubbler and pilot light will be used to capture and treat gases so that it can be safely exhausted.
This initial activation subjects the char to temperatures around 700 °C. The goal is to burn of just enough carbon to maximize the microporosity while still maintaining the structural integrity of the carbon.
The specific temperature ramp up rates will be developed after several Step 1 firings to determine the most efficient program, where the temperature increase/hold will be controlled and recorded.
Step 1 activated carbon will be subsequently cooled and analyzed. Subsequent batches will proceed immediately to Step 2 Activation.
The temperature is increased in the furnace. The goal of this second step is to selectively widen the outer pore mouths and interconnect them into open, continuous mesopore transport channels.
This controlled burn-off to achieve hierarchical micropore / mesoporous balance. During the increased temperature and rate of firing, the steam-carbon reaction is increased exponentially.
With the ideal structural hierarchy of micropores and mesopores established after Step 1 and Step 2, the Hard Activated Carbon product can now be further enhanced to improve the anode efficiency and performance.
More research will be applied to heteroatom doping of activated carbon post-treatment. Co-doping will also be researched and implemented to streamline the process.
The goal is to transition into larger scale production of highly efficient anode material geared towards sodium-ion battery manufacturers.
A byproduct of pyrolysis, Pyroligneous Acid (a.k.a. Wood Vinegar) is collected from our smoke condensers and refined using our proprietary aging/sedimentation, rotary vacuum distillation and fractional distillation system.
Pyroligneous acid is a complex liquid with a pH of between 2.5 to 3.6. It consists of over 200 distinct organic compounds, which vary based on the material and pyrolysis duration and temperature. The general chemical composition of wood vinegar is broken down below:
H2O (80%-90%)
Organic Acids (10%-20%)
Acetic Acid: C2H4O2
Phenolic Compounds (20%)
Syringol-type compounds: 2,6-dimethoxyphenol
Guaiacol-type compounds: 2-methoxyphenol (guaiacol), creosol
Benzenediol-type compounds: catechol
Neutral and Minor Organic Compounds (Fraction)
Alcohols: Methanol, ethanol
Ketones: Acetone, 2-cyclopenten-1-one
Aldehydes: Formaldehyde, furfural
Furans: methoxytetrahydrofuran
Regenco research will focus on efficiently extracting specific isolates. Primary uses of these compounds are in the Perfume and Food industry, but has other important Pharmaceutical and Industrial applications.
Phenolic Compounds (20%)
Syringol (Sweet, Rich, Smoke & Tobacco): Analgesic, Antiseptic, Antimicrobial, Antioxidant, Preservative, Antifungal, Antibacterial, Antioxidant.
Guaiacol (Leather, Smoke, Vanilla Hints): Analgesic, Antiseptic, Antimicrobial Antioxidant, Preservative, Antiseptic, Dental Sedative, Expectorant, Local Anesthetic
Bio-Vanillin (Sweet, Warm, Floral Woody): Antimicrobial, Antioxidant, Preservative, Defoamer, Brightener in Electroplating, Bioplastics
Small batches of about 5L-10L will be processed to ensure 99.9% pure, pharmaceutical grade.
This horizontal airflow carbonization furnace is capable of processing about 3,300 lbs (1,500 kg) of raw material (coconut shells) for about 6 to 8 hours (plus 14 hours for cooling). This amounts to approximately 1,672 (760 kg) lbs of charcoal and 1,500 lbs (682 kg) of wood vinegar daily. The remaining tar is collected to be used as
The twin smoke capture stacks recirculate flue gases (syngas) as fuel and are effectively smokeless. We carbonize only coconut shells in these ovens. Temperatures can reach up to 500 °C.
This split-tube type furnace is critical in controlling the pore development during carbon activation with Steam using Nitrogen (N2) as the inert gas environment.
This furnace can reach temperatures of up to 1300 °C (2192 °F) and is fully programmable to hold or ramp-up/down temperature in precise duration and increments. It can also hold vacuum and create inert environments inside the quartz tube. For safety purposes, an oil bubbler is connected to the output side to prevent oxidation during firings. The output gas are then burnt off or neutralized in a fume scrubber with a pilot light.
This equipment will be used in our advanced R&D of activated carbon anode composites and will be available by mid-2027.
We currently partner with Professor Durga Misra (dmisra@njit.edu) of the New Jersey Institute of Technology (NJIT) Device & Material Characterization Laboratory to perform the pore distribution architecture.
The goal is to obain the precise heating rates and holds, duration, amount of activation gas and monitoring protocols to scale into an efficient industrial operation that is safe and sustainable.
A high-performance benchtop furnace That will be used for moisture & organics burnouts and researching activated carbon composites. It has a 550-cubic-inch chamber with an exclusive internal venturi air exchange system that rapidly exhausts combustion gases to our air scrubbers for faster and cleaner burnouts.
The built-in digital 3-stage controller allows for up to 9 multi-stage programs, delayed start (up to days in advance), and a long-term hold temperature feature.
This equipment provides an accurate measurement of a material's micropore/mesopore distribution, effective adsorptive surface area and general porosity using noble gases.
Materials such as catalysts, carbons, ceramics, fillers, polymers etc. can be tested by generating adsorption and desorption data via physisorption, chemisorption, thermal conductivity detector analysis (TPD/TPO/TPR), and/or vapor sorption.
In compliance with ISO 9277 - Standard for determining the specific surface area of solids by gas adsorption and ASTM D4365 - Standard test method for determining the specific surface area of catalysts:
Nitrogen (N2)
Krypton (Kr) or Argon (Ar)
We use Argon gas for microporous materials and Krypton gas for materials with low surface area.
Lab equipment for testing of AC, including for the Methyl Blue/Iodine test, ash content, acidity and density:
Digital Weighing Scale (calibration certified) with wind protection
Buchi Rotovapor Vacuum Distillation
Fractional Distillation Equipment
Chemistry set (dosing/titration accessories, heating pads, glassware, etc.) for pH, acidity, Iodine and Methylene Blue tests.
Mechanical test equipment for hardness
