Controlled SPAN Electrode Synthesis for and High-Performance Energy Storage Scalable production and enhanced stability through advanced reactor design and transition metal sulfide integration Technology Summary Researchers at Idaho National Laboratory (INL) have developed an integrated approach to producing sulfurized–polyacrylonitrile (SPAN) electrode materials at scale with improved electrochemical performance. This dual innovation combines: Controlled, scalable SPAN synthesis enabled by a custom high-pressure chemical reactor with real-time monitoring and additive reagent control. SPAN–transition metal sulfide composites designed to enhance conductivity, sulfur utilization, mitigate polysulfide formation, prolong cycle life, and increase nominal discharge voltage performance in lithium-sulfur and sodium-sulfur batteries. The combined platform addresses longstanding barriers in SPAN production and performance, opening viable pathways for next-generation rechargeable batteries in grid storage, electric mobility, and defense applications. Problem Addressed Manufacturing barriers: Consistent, high quality SPAN cathode materials are difficult to produce in large batch sizes. Existing methods lack precision, scalability, and safety. Commercial gap: Battery developers and manufacturers lack access to a reliable process to enable large scale SPAN production needed to advance lithium-sulfur and sodium-sulfur chemistries. Solution INL's approach provides both a production pathway and a material enhancement strategy : Reactor-based controlled synthesis Operates under high pressures (up to 3000 PSI) and high temperatures (up to 450°C) with the ability to eliminated headspace for safety and yield. Captures noxious gases and allows gas reagent introduction. Integrates electronic controls, real-time spectroscopy for product feedback, and reproducibility. SPAN–metal sulfide composites Incorporation of transition metal sulfides into the SPAN matrix. Optimized distribution and morphology of sulfides to stabilize cycling and improve conductivity. Potential to increase operating voltage beyond the nominal discharge of 1.85 V for traditional SPAN. Together, these innovations offer a scalable, tunable process to deliver advanced cathode materials for next generation energy storage. Key Advantages Scalability: Controlled batch production demonstrated up to 250 g, supporting pilot-scale manufacturing. Repeatable Material Quality: Batch to batch variability minimized to produce consistent, high-quality material. Safety and efficiency: High-pressure containment, gas capture, and headspace elimination reduce operational risks. Process versatility: Gas reagent introduction and real-time feedback allow tailoring of SPAN properties to specific applications. Market Applications Grid energy storage: Long-duration, cost-competitive solutions for renewable integration. Electric vehicles: Higher energy density cathodes for next-generation EV batteries. Aerospace and defense…