Preliminary engineering and pilot plant design for scalable, non-lithium battery material production supporting strategic process development and future commercialization
A developer of next-generation rechargeable energy storage technology sought to scale its laboratory powder production process into a pilot manufacturing operation capable of supporting future commercial battery production.
The client’s proprietary chemistry offered significant market advantages, including a non-flammable, non-toxic battery platform free of lithium and cobalt while utilizing low-cost and widely available materials.
To support commercialization efforts, the client engaged Re:Build Optimation to develop a pilot powder production facility initially targeted at supporting approximately 1 MWh of annual battery production capacity, nearly 100 times larger than the client’s existing laboratory-scale operation.
The project presented several complex engineering and strategic challenges. The process chemistry was still in the developmental stage, requiring careful evaluation of suitable production methods and scalable unit operations. In addition, the client needed realistic capital expenditure projections early in the design phase to determine the feasibility of the proposed manufacturing scale.
As preliminary engineering progressed, projected capital costs for the original 1 MWh pilot plant were determined to be significantly higher than the client’s available budget and strategic targets. This required both teams to rapidly reassess production goals, optimize the process design, and develop a scaled-down solution capable of fitting within the client’s existing Massachusetts facility while still supporting meaningful pilot-scale production and process development.
Re:Build Optimation began the engagement with a detailed evaluation of the client’s existing laboratory process, including supplied process flow diagrams, material balances, and chemical process data. Working collaboratively with the client’s engineering team, Re:Build Optimation assessed how the lab-scale chemistry could be translated into a scalable and economically viable pilot manufacturing operation.
A key focus of the project involved identifying the most appropriate unit operations and production methods for scaling the proprietary chemistry from laboratory production to pilot manufacturing volumes. The engineering team researched and evaluated multiple process technologies, including reactor configurations, spray drying systems, separation methods, heat transfer equipment, calcination systems, and powder handling strategies.
In parallel, Re:Build Optimation performed techno-economic analysis and factored capital cost estimating to help the client understand the financial implications of scaling to different production capacities. Using industry-standard chemical engineering estimation methodologies, the team generated preliminary CAPEX models and facility sizing studies to support strategic decision-making.
Once the original 1 MWh pilot plant concept was determined to exceed budget expectations, Re:Build Optimation worked closely with the client to pivot the design toward a reduced-capacity solution. The revised concept targeted approximately 100 kWh annual production while maximizing reuse of prior engineering work and adapting the process layout to fit within the client’s existing facility.
Advanced 3D modeling tools and process simulation software were utilized throughout the project to optimize equipment placement, evaluate facility fit-up, and balance process throughput with operator requirements, batch timing, and capital constraints.
Re:Build Optimation developed a comprehensive preliminary engineering package for the pilot powder production facility, delivering both process design guidance and strategic manufacturing insights to support the client’s future commercialization planning.
Key project deliverables and solutions included:
The final design concept provided the client with a significantly refined and strategically optimized pilot production approach aligned with both budgetary constraints and long-term commercialization objectives.
Re:Build Optimation successfully completed preliminary engineering efforts across two project phases, delivering scalable process designs, realistic capital cost projections, and optimized pilot plant concepts that enabled the client to make informed strategic manufacturing decisions.
Although the original 1 MWh pilot facility was ultimately determined to exceed the client’s target investment range, the project provided substantial value by identifying these constraints early in the development process. This allowed the client to pivot toward a more practical pilot production strategy while avoiding significantly larger downstream investment risks.
The revised 100 kWh pilot plant concept successfully reduced projected capital expenditures while fitting within the client’s existing facility footprint and leveraging previously completed engineering work. The resulting design gave the client a clear pathway toward pilot-scale production and future process commercialization.
By combining process engineering expertise, scale-up experience, economic modeling, and collaborative development, Re:Build Optimation helped the client bridge the critical gap between laboratory chemistry and scalable manufacturing strategy.
The pilot plant preliminary engineering included:
Let’s talk about your unique challenges and how Re:Build Optimation can help you.
