Spray-drying as a tool to disperse conductive carbon inside Na₂FePO₄F particles by addition of carbon black or carbon nanotubes to the precursor solution

In this work, Na₂FePO₄F-carbon composite powders were prepared by spray-drying a solution of inorganic precursors with 10 and 20 wt% added carbon black (CB) or carbon nanotubes (CNTs). In order to compare the effect of CB and CNT when added to the precursor solutions, the structural, electrochemical, and morphological properties of the synthesized Na₂FePO₄F-xCB and Na₂FePO₄F-xCNT samples were systematically investigated. In both cases, X-ray diffraction shows that calcination at 600 °C in argon leads to the formation of Na₂FePO₄F as the major inorganic phase. ⁵⁷Fe Mössbauer spectroscopy was used as complementary technique to probe the oxidation states, local environment, and identify the composition of the iron-containing phases. The electrochemical performance is markedly better in the case of Na₂FePO₄F-CNT (20 wt%), with specific capacities of about 100 mAh/g (Na₂FePO₄F-CNT) at C/4 rate vs. 50 mAh/g for Na₂FePO₄F-CB (20 wt%). SEM characterization of Na₂FePO₄F-CB particles revealed different particle morphologies for the Na₂FePO₄F-CNT and Na₂FePO₄F-CB powders. The carbon-poor surface observed for Na₂FePO₄F-CB could be due to a slow diffusion of carbon in the droplets during drying. On the contrary, Na₂FePO₄F-CNT shows a better CNT dispersion inside and at the surface of the NFPF particles that improves the electrochemical performance.