Detailed Project Report on lithium ferro phosphate battery (cap: 120 nos/day)

LITHIUM FERRO PHOSPHATE BATTERY 

(CAP: 120 NOS/DAY)

 [CODE NO.4050]  

A lithium iron phosphate (LFP) battery is a type of lithium-ion battery that is capable of charging and discharging at high speeds compared to other types of batteries. It is a rechargeable battery consisting of LiFePO4 as its cathode material; hence the name.

Lithium iron phosphate batteries have several distinctive features, including:

• Better power density

• Low discharge rate

• Flat discharge curve

• Less heating

• Higher number of charge cycles

• Increased safety

Lithium iron phosphate (LFP) batteries are also known as lithium ferrophosphate batteries.

The first model of the lithium iron phosphate battery was made after the discovery of phosphate as a cathode material for use in li-ion batteries in 1996. Improvements in the coatings and usage of nano-scale phosphate have made this type of battery more efficient.

The major distinction that lithium iron phosphate batteries have from other li-ion batteries is that LFP is capable of delivering a constant voltage and also has a comparatively higher charge cycle, in the range of 2000-3000. LFP batteries are environmentally safe and structurally stable. They have a lower energy density and low discharge rate. They do not heat up easily and are relatively cooler than other batteries. The chemistry of the battery saves it from thermal runaway, and hence it is considered to be safe for home use.

Due to their constant voltage and safe discharge, LFPs have found applications in cars, bicycles and solar devices. They are also used as replacements for costly lead-acid starter batteries. They are well suited for applications that require high-load currents and endurance. They are easy to store and carry due to their light weight and ability to provide huge amounts of energy. They are widely used in portable electronic devices like laptops and mobile phones.

A recent improvement over the original lithium iron phosphate cathode material by MIT has allowed these batteries to be charged up to 100 times faster than the previous speed. An improvised coating of an ion conductor onto the LFP has enabled the acceleration of ions, and thus the charging time has been greatly reduced.

Lithium Iron Phosphate (LiFePO4)

Phosphate based technology possesses superior thermal and chemical stability which provides better safety characteristics than those of Lithium-ion technology made with other cathode materials. Lithium phosphate cells are incombustible in the event of mishandling during charge or discharge, they are more stable under overcharge or short circuit conditions and they can withstand high temperatures without decomposing. When abuse does occur, the phosphate based cathode material will not burn and is not prone to thermal runaway. Phosphate chemistry also offers a longer cycle life.

Lithium Ion Cathode Chemistry Comparison (Used With Carbon Anodes)

Cathode Material Typical Voltage (V) Energy Density Thermal Stability

Gravimeric (Wh/Kg) Volumetric (Wh/L)

Cobalt Oxide 3.7 195 560 Poor

Nickel Cobalt Aluminum Oxide (NCA) 3.6 220 600 Fair

Nickel Cobalt Manganese Oxide (NCM) 3.6 205 580 Fair

Manganese Oxide (Spinel) 3.9 150 420 Good

Iron Phosphate (LFP) 3.2 90-130 333 Very Good

Advantages:

a. Quick charging

b. Safer performance and large overcharge tolerance

c. Self balance

d. Simplified battery management system and battery charger

e. Four times higher energy density than a Lead-acid battery

f. Runs better at high temperature with 10% enhanced capacity

g. Longer life cycle of up to 2000 cycles

COST ESTIMATION

Plant Capacity                                        120 Nos/Day

Land & Building (2500 sq.mt.)              Rs. 2.65 Cr

Plant & Machinery                                   Rs. 2.88 Cr

Working Capital for 2 Months               Rs. 103.27 Cr

Total Capital Investment                       Rs. 109.09 Cr

Rate of Return                                         34%

Break Even Point                                     31%

• INTRODUCTION
• LITHIUM IRON PHOSPHATE (LIFEPO4)
• LITHIUM ION CATHODE CHEMISTRY COMPARISON (USED WITH 
•    CARBON ANODES)
• ADVANTAGES:
• CONSTRUCTION OF LITHIUM FERRO PHOSPHATE BATTERY
• CHARGING AND DISCHARGING PHENOMINA IN LI ION BATTERY
• SAFETY FACTOR IN LITHIUM ION PHOSPHATE BATTERIES
• CHARACTERSTICS OF LIFEPO4 BATTERIES
• DIFFERENT SHAPES OF LITHIUM FERRO PHOSPHATE CELLS
• USES AND APPLICATION
• ADVANCE APPLICATION OF LIFEPO4 IN HEV
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART FOR BATTERY ASSEMBLING
• ASSEMBLING PROCESS OF LITHIUM ION BATTERY
• 1. CELL SORTING:
• 2. MODULE ASSEMBLY:
• 3. PACK ASSEMBLY:
• 4. FINAL TESTING AND STORAGE:
• EQUIPMENTS FOR AUTOMATIC ASSEMBLY
• 1. LINEAR WORKPIECE CARRIER TRANSFER SYSTEM
• 2. PRE-ASSEMBLY STATION
• 3. AUTOMATIC MODULE ASSEMBLY STATION
• 1. ASSEMBLY OF SECOND SIDE PLATE
• 2. AUTOMATIC LINE CHANGE
• 3. AUTOMATIC LASER WELDING STATION
• MARKET POSITION
• INDIA LITHIUM-ION BATTERY MARKET
• DECREASING COST OF LITHIUM-ION BATTERIES - TO SUPPLEMENT 
•    THE DEMAND
• RENEWABLE-BASED ENERGY STORAGE - OPPORTUNITY FOR GROWTH
• ELECTRIC VEHICLES & LITHIUM ION BATTERY MARKET, INDIA, 2017
• CHANGING LANDSCAPE OF THE ENERGY SECTOR, INDIA, 2017-2030
• INDIA LITHIUM-ION BATTERIES MARKET TO GROW AT OVER 35% 
•    CAGR TILL 2020
• INDIGENIZATION OF LITHIUM-ION BATTERY MANUFACTURING
• A TECHNO-ECONOMIC FEASIBILITY ASSESSMENT
• GLOBAL LIB PRODUCTION AND PRICE TREND
• LIB DEMAND IN INDIA: PROJECTIONS FOR 2030
• ECONOMICS OF LIB MANUFACTURING: 50 GWH PLANT
• ANALYSIS & RECOMMENDATIONS
• BATTERY MARKET POSITION
• GLOBAL CONTEXT AND IMPACT
• KEY CHALLENGES TO SCALING INDIA’S BATTERY INDUSTRY
• A. LOW MINERAL RESERVES
• B. EARLY-STAGE BATTERY MANUFACTURING INDUSTRY
• C. LACK OF COORDINATION AMONG STAKEHOLDERS
• D. HIGH PERCEIVED RISK
• PLANT LAYOUT
• PRINCIPLES OF PLANT LAYOUT
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
• PLANT LOCATION FACTORS
• PRIMARY FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• 6. TRANSPORTATION:
• 7. WASTE DISPOSAL:
• 8. LABOR:
• 9. REGULATORY LAWS:
• 10. TAXES:
• 11. SITE CHARACTERISTICS:
• 12. COMMUNITY FACTORS:
• 13. VULNERABILITY TO WARTIME ATTACK:
• 14. FLOOD AND FIRE CONTROL:
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• 1. DEPRECIATION:
• 2. FIXED ASSETS:
• 3. WORKING CAPITAL:
• 4. BREAK-EVEN POINT:
• 5. OTHER FIXED EXPENSES:
• 6. MARGIN MONEY:
• 7. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• SUPPLIERS OF LIFEPO4 BATTERY PACK
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF LI ION FE PO4 CELL
• CHINA SUPPLIERS FOR LIFEPO4 CELL
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF ASSEMBLY LINE
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSORS
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
• SUPPLIERS OF SUBMERSIBLE WATER PUMP

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)