Progresses in lithium ion battery (LIB) materials are increasing by the development of new synthesis methods where the production of materials in a scalable and continuous route is very critical when the process development transfers to large scale quantities. In a LIB, one of the most performance limiting components is the cathode, which also limits the overall performance of the battery. Among the other synthesis methods, co-precipitation from aqueous processes is known to yield the best cation mixing within the structure, in particular for the synthesis of cathode precursors for batteries. Continuous stirred tank reactor (CSTR) is by far the most widely used systems utilized in battery industry, yet have low reproducibility, product efficiency, and undergo from very long stabilization times due to low mass transfer rate.

Here, we report a new emerging technology, Taylor Vortex Reactor (TVR), for the cathode precursor synthesis which overcomes many complexities encountered in CSTRs. As current research in the field is trending towards exploring nickel-rich compositions, we produced Ni_0.6Mn_0.2Co_0.2 (OH)₂ precursors employing a continuous hydroxide route in a TVR which were then lithiated to form active cathode particles. The effect of rotation speed on the morphology, and particle size and distribution of the precursors were investigated and reported.  In general, higher rotation speed favored spherical particle formation with a smooth surface morphology along with a narrow particle size distribution. Tap densities of 1.77 – 1.98 g/cc for the precursor and 2.02 – 2.24 g/cc for the active materials were achieved, delivering 173 – 186 mAh/g discharge capacities at the first cycle with a C-rate of 0.1C when cycled between 4.3 - 3.0V.