Complete Technology Hand Book on Lithium Ion and Lead-Acid Batteries Manufacturing and its Recycling

Batteries have quietly woven themselves into the fabric of our modern lives, powering our smartphones, laptops, electric vehicles, and a myriad of portable devices that have become indispensable. As we stand on the cusp of an era where clean and sustainable energy solutions are imperative, batteries have taken center stage, promising to revolutionize the way we store and use energy. It is within this transformative landscape that this comprehensive handbook, "Complete Technology Handbook on Lithium Ion and Lead-Acid Batteries Manufacturing and Its Recycling," finds its purpose.

The story of batteries is a fascinating journey that has evolved over centuries, with each advancement bringing us closer to the dream of efficient, eco-friendly energy storage. This book, presented through a detailed and carefully structured series of chapters, is designed to take you on this journey. It explores the principles of operation, the inner workings of lithium-ion and lead-acid batteries, and the chemistry behind their functionality. It also delves into the design considerations, manufacturing processes, and end-user applications that have become essential aspects of the battery industry.

One of the striking features of this handbook is its commitment to embracing the full spectrum of battery technology, from the sturdy and trusted lead-acid batteries that have served us for generations to the cutting-edge lithium-ion batteries that are poised to redefine the way we harness energy. Understanding the past and present is essential to shaping the future, and we provide insights into the developments, trends, and limitations of both these battery technologies.

Moreover, the book ventures into the world of recycling, a topic of growing significance in a world that is increasingly concerned with sustainability. As the demand for batteries continues to rise, so too does the importance of recycling and managing the environmental impact of used batteries. The handbook discusses various recycling methods and technologies, ensuring that this aspect of battery production is not overlooked.

In a rapidly changing technological landscape, it is crucial to have access to accurate and comprehensive information. This handbook not only serves as a reference guide for industry professionals and manufacturers but also extends its reach to budding entrepreneurs and students eager to explore the potentials of the battery manufacturing sector. Whether you aim to start your battery business or simply wish to gain a deeper understanding of the batteries that power your daily life, this book offers valuable insights into the intricacies of battery design, production, and recycling.

To achieve this comprehensive scope, the book draws upon the expertise of various contributors, including industry experts and professionals who have dedicated their careers to the field of battery technology. It also benefits from the vast resources and knowledge available in the public domain, making it a one-stop resource for all your battery-related queries.

In an age where technology is driving innovation at an unprecedented pace, this handbook aims to be a beacon of knowledge, a guide to understanding the very core of the devices that keep our world connected and powered. We invite you to embark on this enlightening journey through the pages of "Complete Technology Handbook on Lithium Ion and Lead-Acid Batteries Manufacturing and Its Recycling," and we hope it serves as a valuable resource in your quest to unravel the secrets of battery technology.

The book contains chapters on Introduction, Battery Design and Function, Industrial Battery Outlook, Future Scope of Lithium Ion Batteries, Future of Lithium-Ion Batteries And Electrification, Lithium Ion Battery, Lithium-Ion Battery Applications, Lithium Battery Manufacturing, Recycling of Lithium-ion Batteries, Aluminium-air Battery, Alkaline Batteries, Metal-Air Battery, Lead-Acid Batteries, Lead-Acid Batteries: Fundamentals, Technologies, and Applications, Lead-Acid Battery Manufacturing Equipment, Lead-Acid Battery Recycling, Zinc-Carbon Battery, International Standards and Testing Applicable to Batteries, Battery Smelting and Lead Refining, Dry Lead Acid Battery, Lithium Ferro Phosphate Battery, Lithium Ion Battery Container, Lithium-Ion Batteries Manufacturing Unit, Pouch Cell Manufacturing Plant, Recycle of Lead Acid Battery, Secondary Lithium Ion Manufacturing (Lithium Ion Battery Pack), Solar Lead Acid Battery.

ISBN: 9788189765071

Chapter 1

Introduction 

Principles of Operation 

How Lead Acid Battery works 

Chemical Action During Discharging 

Chemical Action During Recharging 

Primary batteries 

Zinc–manganese dioxide systems 

Zinc–mercuric oxide battery 

Zinc–silver oxide battery

Lithium batteries 

Air-depolarized batteries 

Other primary battery systems 

Storage batteries

Lead-acid batteries 

Alkaline storage batteries 

Lithium storage batteries 

Development of batteries 

Contents-cum-Index

Chapter 2

Battery Design and Function 

Lithium Ion Battery Electrochemistry and Function 

Functions 

Electrochemistry behind rechargeable lithium ion batteries 

Charge and discharge 

Considerations in selection of Cathode, Anode and Electrolyte 

Anode material should exhibit the following properties 

Cathode material should exhibit the following properties 

Electrolytes should exhibit the following properties 

Cylindrical vs Prismatic Cell Design Tradeoffs 

Battery Module Design Approach 

Modular circuit board 

Safety Considerations 

Best Practices for lithium-ion Cell/Battery Use 

Transporting batteries 

Charging/Discharging 

Storage 

Chapter 3

Industrial Battery Outlook 

Market dynamic – global lead acid battery market 

Lead acid battery market segmental overview 

Rapid technological advancements and expansion in the telecom sector to boost market growth 

Lead Acid Battery Market Segment Insights 

Lead Acid Battery Product Insights 

Lead Acid Battery Construction Method Insights

Lead Acid Battery End-User Insights 

The Lead-Acid Segment Expected to Dominate the Market 

Lead acid battery market by technology 

Lead acid battery market by end user 

Lead acid battery market by construction method 

Lead acid battery market by type 

Lead acid battery market by industrial 

Lead acid battery market by geography 

Lead acid battery market key players 

Asia Pacific Lithium Ion Battery Market Overview

Asia Pacific Lithium Ion Battery Market Segmentation 

Regional Market Outlook 

High Cost of Li-ion Batteries-Major Challenge 

Covered in this Asia Pacific lithium ion battery market report 

Key Market Players 

Chapter 4

Future Scope of Lithium Ion Batteries 

Five key performance characteristics of battery technology evolution 

Key battery technology Performance characteristics

Present Day Lithium Ion Batteries 

Deficiencies of Present Lithium Ion Batteries and Likely Improvements 

Li-Ion Batteries are Amazing Energy Storage Devices 

The Future of Li-Ion Energy Storage 

A Finite Resource 

Early Li-Ion Battery Development 

Benefits of a Lithium Ion Battery 

Importance of Lithium Ion Batteries at Hiden Analytical 

Chapter 5

Future of Lithium-Ion Batteries and Electrification 

Major Trends 

Future Trends in Battery Technology 

NanoBolt lithium tungsten batteries 

Zinc-manganese oxide batteries 

Organosilicon electrolyte batteries 

Gold nanowire gel electrolyte batteries 

TankTwo String Cell™ batteries 

Chapter 6

Lithium Ion Battery 

Characteristics of lithium-ion batteries 

How do lithium-ion batteries produce electricity? 

Advantages 

Benefits of lithium-ion batteries 

Classification 

Lithium Cobalt Oxide 

Lithium Manganese Oxide 

Lithium Iron Phosphate (LFP) 

Lithium Nickel Manganese Cobalt Oxide (NMC) 

Lithium Nickel Cobalt Aluminum Oxide

Lithium Titanate 

Chemistry 

Cathode Materials 

Electrolyte 

Cells Couples and Reaction Mechanisms 

Characteristics of lithium primary batteries 

Summary of Design and Performance Characteristics 

Soluble-Cathode Lithium Primary Batteries 

Solid-Cathode Lithium Primary Cells 

Safety and handling of lithium batteries 

Factors Affecting Safety and Handling 

Safety Considerations 

Lithium/Sulfur Dioxide (Li/SO2) Batteries 

Chemistry 

Construction 

Performance 

Voltage 

Cell and Battery Types and Sizes 

Alkaline Batteries 

Coin Cell Batteries 

What is a Secondary Cell? 

Lead-acid Batteries 

Ni-Cd Battery 

Ni-MH Battery 

Li-ion Battery 

Li-Po battery

Use and Handling of Li/SO2 Cells and Batteries-Safety Considerations 

Applications 

Lithium/Thionyl Chloride (Li/SOCl2) Batteries 

Chemistry 

Advantages of Li-SOCl2 

Usage of Lithium Thionyl Chloride Batteries 

Lisocl2 Bobbin Battery 

Elecorev Battery Has Long Storage Lifetime 

Specifications 

Spirally Wound Cylindrical Batteries 

Increasing the Plate Area

Characteristics of a Spiral Wound Battery 

Flat or Disk-Type Li/SOCl2 Cells 

Large Prismatic Li/SOCl2 Cells 

Chapter 7

Lithium-Ion Battery Applications

Applications of Li-Ion Batteries 

Automotive Applications for the Lithium-Ion Batteries 

Starting Lighting Ignition 

Idle Stop 

Full Hybrid 

Mild Hybrid 

Microhybrid electric vehicles 

Hybrid electric vehicles 

Plug-in hybrid electric vehicle and range extended electric vehicle 

Electric Vehicle 

Plug-in Hybrid Electric Vehicle 

Public Transportation 

Robotics and Autonomous Applications 

Features 

Industrial Applications 

Marine and Maritime Applications 

Grid and Stationary Applications 

Bulk Energy Storage 

Ancillary Services 

Customer Energy Management Services 

Li-ion Battery for Numerous Applications 

Future of Li-Ion Batteries 

Chapter 8

Lithium Battery Manufacturing 

Electrode Coating 

Cell Assembly 

Prismatic Cells 

Cylindrical Cells 

Terminal Welding 

Challenges 

Canning or Enclosing 

Challenges 

Filling 

Challenges 

Formation  

Process Control 

Support Services 

Challenges 

Ageing 

Challenges 

Final Control Checks

Lithium ion Battery Pack Assembly Line Making Machine 

Battery Cell Tester 

Types of Battery Tester 

Automatic Li-ion Battery Pack Production Line 

Technical Specification 

Machine Features 

Battery Production Information Management System 

Automatic Battery Cell Sorting Machine for Cylindrical Lithium Battery 

Features 

Spot Welding Machine for Lithium Ion battery 

Product Specification 

Product Description 

Integrated Tester 

Performance Characteristics: 

Charging and Discharging Aging Testing Machine 

Function Features 

Chapter 9

Recycling of Lithiumion Batteries 

Repairing and Remanufacturing 

Mechanical processing 

Hydrometallurgical processing 

Repairing and Remanufacturing 

Raw Materials

Technical Process 

Technical Standards 

Remanufacturing 

Refurbishing 

Repurposing 

Energy storage system concept demonstration 

Second-Life Lithium Battery 

Overcoming obstacles 

Lithium-ion Battery Recycling - Process & Equipment 

Filter Press – Removal of the Black Mass

Evaporation and Heated Tank System

Filter Press – Removal of the Lithium Carbonate

Filter Press Features 

Clarifier 

Sludge Dryer 

Thermal Evaporators 

Reverse Osmosis (RO) 

Ultrafiltration 

Atmospheric Evaporators 

Chapter 10

Aluminium-air Battery 

Electrochemistry 

Materials and Methods 

Materials 

Hydrogen Evolution and Half-Cell Test 

Full-Cell Test 

Aluminium-air battery: discovery, commercial alloys and state of the art. 

Discovery and production 

Commercial aluminium alloys. 

Chapter 11

Alkaline Batteries 

Advantages of Alkaline Battery 

Disadvantage of Alkaline Battery 

Construction of Alkaline Battery 

Chemistry in Batteries 

Electrochemistry 

Alkaline Battery Chemicals 

Temperature Effects on Performance

Capacity 

Voltage 

Shelf Life 

Discharge types 

Constant resistance (B) 

Constant current (A) 

Constant power (W) 

Testing / Care / Warnings: 

Testing 

Care and Handling Do’s: 

Care and Handling Don’ts 

Warnings 

Design and Safety Considerations 

Current 

Recharging of alkaline batteries 

Leaks 

Disposal 

Uses of Alkaline Batteries 

Alkaline Battery Recycling Industry 

Improving efficiency and quality 

Production of other battery minerals 

Key process steps 

Key benefits 

How are Batteries Made? 

The Manufacturing Process 

The separator 

The anode 

The seals 

The label 

Quality Control 

Chapter 12

Metal-Air Battery 

Lithium-air battery 

Aluminum-air battery 

Zinc-air battery 

Sodium-air battery 

Magnesium-air battery 

Potassium-air battery 

Iron-air battery 

Chapter 13

Lead-Acid Batteries 

Introduction 

Construction 

Container 

Plates 

Active Component 

Separators 

Battery Edges 

Lead Acid Battery Working Principle 

Different Types 

Lead Acid Battery Chemical Reaction 

Life 

Lead Acid Battery Applications 

Battery Efficiency 

Lead Acid Battery Configurations 

Special Considerations for Lead Acid Batteries 

Boost Charging 

Specific Gravity (SG) 

Special Considerations for Gelled, Sealed Lead Acid Batteries 

Failure Modes for Lead Acid Batteries 

Installation 

Safety 

Maintenance 

Battery Disposal and Recycling 

Electrode Materials and Configuration 

Electrode Configuration 

Battery Housing 

Potential Problems with Lead Acid Batteries 

Corrosion of terminals 

Self-Discharge 

Change in form of materials 

Modifications to the electrolyte 

Electrolyte Volume and Concentration 

Captive Electrolyte Lead Acid Batteries 

Typical Commercially Available Battery Units 

Use Pattern of Lead-Acid Batteries 

Charge-Discharge Procedures of Lead-Acid Batterie 

Non-automobile applications of lead-acid batteries 

Stationary Applications of Lead-Acid Batteries 

Standby Applications of Lead-Acid Batteries 

Backup Power Applications of Lead-Acid Batteries 

Automobile applications of lead-acid batteries 

Automobile Starting-Lighting-Ignition Applications 

Electric and Hybrid Electric Vehicle Applications of Lead-Acid Batteries 

Chapter 14

Lead-Acid Batteries: Fundamentals, Technologies, and Applications 

Introduction 

Materials and Properties

Porosity, Pore Size, and Pore Shape 

Ionic Resistance 

Electrochemical Compatibility 

Acidic and Oxidation Stability 

Puncture Resistance 

Surface Area 

Separator Synthesis 

Polyethylene Separator 

Absorptive Glass Mat Separator 

Darak® Separator 

Rubber Separators 

Separator Structure Design and Fabrication 

Positive Ribs 

Negative Ribs 

Embossed/Corrugated 

Compression/Resiliency 

Fabrication 

Effects of material composition, morphology, and synthesis conditions on battery performance

Antimony Poisoning and Water Loss

Low Electrical Resistance 

Effect of battery operating conditions on separator performance 

Basic Condition/Extreme Shrinkage 

Hydration Shorts 

Extreme Oxidation 

Technical challenges, mitigation strategies, and perspectives 

High-Power Starter Batteries 

Deep-Cycle Batteries 

Chapter 15

Lead-Acid Battery Manufacturing Equipment 

Grid Casting 

Grid Caster 

Strip Expansion Grid 

Continuous Grid Caster 

Lead Oxide Production 

Barton Pot Process 

Ball Mill Process 

Paste Mixing 

Batch Paste Mixer 

Continuous Paste Mixer 

Pasting

Curing 

Formation 

Formation of Positive Plates 

Formation of Negative Plates 

Tank Formation 

Case Formation 

Battery Assembly 

Group Stacking 

Alignment 

Group Burning 

Group Alignment 

Group Insertion 

Inspection and Terminal Alignment 

Short Circuit Testing 

Intercell Welding 

Shear Testing 

Case Cover Sealing 

Leak Testing 

Terminal (Post) Burning 

Aluminum Foil Sealing 

Acid Filling 

Packing 

Quality assurance and control 

Chapter 16

Lead-Acid Battery Recycling 

Battery Breaking 

Historical Background of Battery Breaking 

Modern Battery Breaking Process 

Battery Breaking: Potential Sources of Environmental Contamination 

Lead Reduction 

Pyrometallurgical Methods 

Hydrometallurgical Methods 

Lead Reduction: Potential Sources of Environmental Contamination

Lead Refining 

Pyrometallurgical Refining 

Lead Refining: Potential Sources of Environmental Contamination 

Lead Battery Recycling Plant

Lead Battery Recycling Process 

Scope

Equipment for Setting Up Lead Battery Recycling Plant 

Battery Cutting Machines/Battery Breakers 

Breaking System & Separation of Components 

Battery Cutting and Punching Machine Benefits: 

Lead Rotary Furnace 

The Battery breaking floor Area 

Plastic Waste Storage Area 

Furnace Oil/LDO (if used) Storage 

Carbon Storage 

Smelting/Refining and Casting Area 

Cooling cum Settling Chambers 

Cyclone separators 

Bag Filters

ID Fan 

Alkaline Scrubber

Stack 

Effluent Treatment Plant (ETP) 

Hazardous waste Storage 

Product Lead Ingot Storage 

Choice of Smelting Furnace 

Refining Pots 

Lead Ingoting casting systems 

Chapter 17

Zinc-Carbon Battery

Characteristics 

Chemistry 

Construction 

Cylindrical Cell 

Carbon cathode 

Manganese dioxide 

Electrolyte 

Carbon rod 

Separator 

Seal 

Jacket 

Electrical contacts 

Inside Out Cylindrical Construction 

Flat Cell and Battery 

Voltage Rating of Zinc Carbon Battery 

Energy Density of Zinc Carbon Battery Cell 

Types of Zinc Carbon Battery 

Advantages and Disadvantages of Zinc Carbon Battery 

Advantages of Leclanche’ Battery 

Disadvantages of Leclanche’ Battery 

Advantages of Zinc Chloride Battery 

Disadvantages of Zinc Carbon Battery 

Chapter 18

International Standards and Testing Applicable to Batteries 

International Safety Standards for Batteries 

General Battery Standards 

Lithium Battery Standards 

Nickel Metal Hydride Battery Standards 

Nickel Cadmium Battery Standards 

Lead Acid Battery Standards 

Photovoltaic Battery Standards 

Safety Standards 

STRD Low Voltage Directive 

Automotive Battery Standards 

Aircraft Battery Standards 

Military Standards for Batteries, Software, EMC/RFI, Safety & Quality 

Radio Battery Standards 

Standby Power Systems Standards 

Software Standards 

EMC/RFI Standards 

Ingress Protection (IP) Standards 

Battery Monitoring Standards 

Battery Recycling and Disposal Standards 

Other Related Electrical Standards 

Quality Standards 

CTIA Authorized Testing Laboratory (CATL) 

Lithium battery testing and certification 

Global battery safety standards and regulations 

Chapter 19

Plant Economics on Battery Smelting and Lead Refining 

Introduction 

Battery Smelting and Refining Of Lead 

Process Flow Chart 

Manufacturing Process 

Scrap Pretreatment 

Smelting 

Refining 

Varta Process 

MA & CX Process 

Scrap Pretreatment 

Battery Breaking Process 

Battery Breaking 

Pollution Control Process 

Pollution Management Plan 

Lead Plant Pollution Control 

Furnace 

Settling Chamber 

Gravity Chamber/Cooling Tower 

Cyclone 

Bag House 

Stack 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum 

Chapter 20

Plant Economics on Dry Lead Acid Battery 

Introduction 

Working Principle of Lead Acid Battery 

Construction and components of dry lead acid battery 

Construction 

Container 

Plates 

Active Component 

Separators 

Battery Edges 

Steps in battery manufacturing process 

Manufacturing Steps of Lead-Acid Batteries 

Oxide and Grid Production Process 

Pasting and Curing 

Assembling the Elements 

Filling and Formation 

Manufacturing Process in Details 

List of raw material 

Manufacturing Plastic Container and Cover 

Manufacturing Process of PVC/ABS Battery Container 

Plate Preparation

Tubular Plate 

Manufacturing process of flat plate

Lead Oxide Preparation 

Grid Casting: 

Paste Preparation 

Pasting Process 

Curing and Drying: 

Assembly 

Group stacking 

Group burning 

Group strapping 

Group insertion 

Heat sealing 

Post burning 

Leak testing 

Formation 

Cell packing: 

Acid filling: 

Testing of battery 

Static Battery Voltage Test 

Plant Economics

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum 

Chapter 21

Plant Economics on Lithium Ferro Phosphate Battery 

Introduction 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum 

Chapter 22

Plant Economics on Lithium Ion Battery Container 

Introduction 

Indigenization of Lithium-Ion Battery Manufacturing 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment

Turn Over/Annum 

Chapter 23

Plant Economics on Lithium-Ion Batteries Manufacturing Unit

Introduction 

Plant Economics 

Land & Building 

Plant & Machinery

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum 

Chapter 24

Plant Economics on Pouch Cell Manufacturing Plant 

Introduction 

Main advantages 

Main disadvantages

Manufacturing Process Pouch Cell 

Material preparation and mixing 

Preparing the Electrodes 

Process Flow Chart for Li Pol Pouch Cell Manufacturing 

For Production 

For Assembling 

Coating and Drying 

Calendaring 

Separation and Drying 

Package assembly 

Combining Electrodes 

Pumping Electrolyte into the Cell 

Polymer Electrolytes

Assembling the Pouch Cell 

Contacting, housing and filling with electrolyte

Forming and Aging Process 

Ambient Conditions for Cell Production 

Testing Process 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum 

Chapter 25

Plant Economics on Recycle of Lead Acid Battery 

Battery Life 

Raw Material 

Lead Battery Breaking and Separation

Desulphurization System 

Lead Refining and Alloying 

Lead Casting 

Gas cleaning system 

Off-gas cleaning system of a lead recycling furnace 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum 

Chapter 26

Plant Economics on Secondary Lithium Ion Manufacturing (Lithium Ion Battery Pack) 

Introduction 

Construction of LI Ferro Phosphate Battery

Construction Material 

Composition of Lithium-ion Batteries 

Cathode 

Anode

Electrolyte 

Separator 

Cathode Materials 

Anode Materials 

Electrolytes 

Separators 

Size of Lifepo4 Cylindrical Cell 

Manufacturing process of lithium ion battery 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month 

Total Capital Investment 

Turn Over/Annum 

Chapter 27

Plant Economics on Solar Lead Acid Battery 

Introduction 

Lead Acid Battery Plates 

Plante Plate 

Structure of Plante Plate 

Faure Plate 

Manufacturing Process 

Plant Economics 

Land & Building 

Plant & Machinery 

Fixed Capital 

Working Capital Requirement/Month

Total Capital Investment 

Turn Over/Annum