Enhanced cycle stability of micro-sized Si/C anode material with low carbon content fabricated via spray drying and in situ carbonization

Highlights: • Micro-sized Si/C composites were fabricated via. spray drying and carbonization. • Multi-morphology carbon was formed in the Si/C composites. • Si/C composite with 5.6 wt.% C provides significant improved cycling stability. • Multi-morphology carbon plays effective role in improving the electrochemical property. • The method provides potential for mass production of superior Si-based anode materials. - Abstract: Micro-sized Si/C composites with in situ introduced carbon of multi-morphology were fabricated via spray drying a suspension of commercial micro-sized Si and citric acid followed by a carbonization. Different ratios of Si to citric acid were used to optimize the composition and structure of the composites and thus the electrochemical performance. Carbon flakes including crooked and flat ones were well dispersed in between the Si particles, forming Si/C composites. Floc-like carbon layers and carbon fragments were also found to cover partially the Si particles. The Si/C composite with a low carbon content of 5.6 wt.% provides an initial reversible capacity of 2700 mA h/g and a capacity of 1860 mA h/g after 60 cycles at a current density of 100 mA/g as anode material for lithium-ion batteries (LIBs), which are much higher than those of pristine Si and the Si/C composites with higher carbon content. The mechanism of the enhancement of electrochemical performance of the micro-sized Si/C composite is discussed. The fabrication method and the structure design of the composites offer valuable potential in developing adaptable Si-based anode materials for industrial applications