Lars Herlitz will be one of the speakers at the Hungarian Battery Week, taking place in Budapest on 6-8 November 2024.
For the past 25 years, battery industry experts and researchers have tried to make lithium-sulfur batteries work effectively as they could provide a viable alternative to existing lithium-ion batteries. The challenge was enormous due to the difficulty of containing sulfur in small particles. US-based startup Lyten had a technological breakthrough and, in 2017, started producing its first batteries, today ready for market entry.
Last week, the company announced plans to invest more than 1 billion US dollars to build the world’s first lithium-sulfur battery gigafactory. We spoke with Lars Herlitz, Chairman and Co-Founder of Lyten, about the main drivers behind the company’s technological breakthrough, the advantages of lithium-sulfur batteries compared to traditional lithium-ion technology and the attractiveness of Hungary as a battery manufacturing hub in Europe.
Lars Herlitz. Photo courtesy of Lyten.
“Establishing operations in a new location without an existing workforce is challenging,” Mr Herlitz begins, mentioning the reasons behind the choice of Reno, Nevada, as the location for this gigafactory. “We are working closely with local communities, governments, educational centres and colleges to prepare the workforce for the new jobs we’re creating.”
Indeed, the cooperation goes both ways. The region’s infrastructure and workforce can contribute to the success of the project, and in turn, the project will have a huge impact on the local community, both in terms of job creation and long-term economic benefits.
The initial milestone is achieving a production capacity of 2 gigawatt-hour (GWh) per year in 2027, with plans to scale up to 10 GWh at full capacity.
Lithium-sulfur (Li-S) batteries are said to have significant advantages over traditional lithium-ion technology as well as lithium iron phosphate (LFP) batteries.
“Switching to LFP is often driven by cost advantages and the absence of cobalt and nickel, but the downside is lower energy density,” Mr Herlitz explains. “LFP batteries are heavier and provide a shorter range. While the energy density of our lithium-sulfur batteries is significantly higher, the cost is also lower because we use fewer materials. Furthermore, our batteries support a more localised supply chain, reducing dependency on imported components like graphite.”
Lithium-sulfur batteries can also simplify the recycling process and reduce the overall ecological impact.
“The current recycling process for batteries is complicated by leakage and safety concerns,” points out Mr Herlitz. “With lithium-sulfur, sulfur is easier to manage and lithium is the only element that needs to be recycled, making the process simpler and safer.”
“Our production process is also environmentally friendly, avoiding the use of toxic chemical binders,” he continues. “It’s water-based, creating a safer environment for both the workforce and the surrounding area, with a lower carbon footprint.”
One of the biggest challenges with lithium-sulfur batteries has been the polysulfide shuttle effect, where sulfur in the cathode tends to degrade during charge and discharge cycles, causing a loss of energy density and reducing the battery’s lifespan. Solving this issue was a crucial step toward making lithium-sulfur batteries commercially viable.
Photo courtesy of Lyten.
“After 25 years of research, we have developed a solution using a material similar to a sponge, with 80 per cent porosity, that holds the sulfur in place while remaining electrically conductive and rigid,” highlights the co-founder of Lyten, emphasising how their 3D graphene material has been key to overcoming this hurdle.
As with all batteries, Li-S batteries go through expansions and contractions during discharge, which cause mechanical stress. However, Mr Herlitz is not worried that this will increase the complexity and costs of manufacturing Li-S batteries.
“Our 3D graphene design helps control this issue,” he says. “We’ve engineered our anodes to work in tandem with the cathodes, so our batteries do not expand and contract more than other types. By minimising expansion and designing the electrodes to offset each other’s movements, we avoid mechanical stress. This also allows us to use thinner cylindrical forms, making the batteries lighter.”
Speaking of the scalability of the project, Li-S batteries well adapt to temperature-related issues. In lithium ion, high temperatures can accelerate degradation, while low temperatures slow down reactions, reducing efficiency.
“Our batteries are designed to handle a broader temperature range than lithium-ion batteries, operating efficiently even in high temperatures without additional cooling and tolerating temperatures as low as -35°C,” says Mr Herlitz, adding that removing the need for heating and cooling also helps saving energy in the operations as a whole.
While Lyten plans to initially begin delivering commercial cells in 2025 for sectors like micromobility, space, drones and defence, there is a huge potential for lithium-sulfur batteries in the EV market, confirmed by the increasing demand.
“We are also working with automotive and transport companies, including trucking companies, to ensure that our batteries are fully market-ready by 2027,” says Mr Herlitz. “Our collaborations with European manufacturers position us to meet this rising demand, providing a next-generation alternative to lithium-ion technology that supports a more sustainable and localised supply chain.”
Lyten’s technology can definitely help address concerns about supply chain dependence on countries like China, both for the US and Europe, which are working to diversify their battery supply chains. In fact, without relying on critical minerals like graphite, nickel, manganese or cobalt, this dependence is drastically reduced.
“This is a major advantage of our chemistry,” underlines Lars Herlitz. “The materials we use are locally available and extracted in environmentally safe ways. Sulfur, for example, is a byproduct of many industrial processes. Our 3D graphene comes from a carbon sequestration process, transforming gas into hydrogen and 3D Graphene. Additionally, we can extract lithium from salty brines rather than through traditional mining methods, which is particularly abundant in places like Hungary.”
Indeed, Lyten is looking at Hungary as the preferred place to outsource operations and enter the European market.
“Europe is a key focus for us and we are looking to partner with organisations there,” he reveals. “We have a subsidiary in Hungary, not only for factory development but also to advance our R&D efforts. Hungary is an attractive location due to strong support from the government and its renowned role as a battery manufacturing hub in Europe.”
Europe has also a very favourable legislative and regulatory framework which, according to Mr Herlitz can be compared to the Inflation Reduction Act (IRA) in the US.
“The IRA has been crucial, offering tax credits of up to 38 US dollars per kilowatt-hour (kWh,) which our technology fully qualifies for due to its local supply chain,” he says. “We’re also exploring opportunities in other states, including repurposing former coal mines, thus creating jobs in regions that have lost employment due to mine closures.”
“The regulatory frameworks in Europe and the US are quite similar,” he continues, “and our environmentally friendly approach aligns well with European standards, especially since we avoid toxic chemicals in our production.”
Looking ahead, Lyten will prioritise tech leadership by investing heavily in advanced R&D.
“We aim to create a workplace that attracts and nurtures top talent,” Mr Herlitz notes. “While we focus on staying ahead in technology, we also believe in partnering with existing battery manufacturers to scale lithium-sulfur production.”
Finally, Mr Herlitz argues that success would mean expanding beyond the Reno plant, utilising repurposed facilities and converting infrastructure initially built for lithium-ion production.
“With lower costs and scalable technology, lithium-sulfur batteries will become a key component in the global shift towards sustainable energy,” he concludes, hoping to partner with different organisations worldwide, turning competition into cooperation for the greater good.