Detailed Project Report on lithium-ion and lithium polymer batteries manufacturing

LITHIUM-ION AND LITHIUM POLYMER 

BATTERIES MANUFACTURING

[CODE NO.4008] 

Electrochemical storage systems will increasingly gain in importance in the future. This is true for the energy supply of computers and mobile phones that are becoming more and more sophisticated and smaller. It is also true for power tools and electric vehicles as well as, on a larger scale, for stationary storage of renewable energy.

Lithium-ion battery packs are complex systems of interrelated components and subsystems but can be relatively easily understood by most people because the pack is the thing that we can touch, hold, and feel. But understanding the lithium-ion chemistries and the physics and chemical reactions that occur inside those battery cells requires gaining an understanding of an even more complex set of systems and interrelationships that are really well understood only by those few chemists, researchers, and cell engineers who work with them on a daily basis. And there is even a lot that they do not under- stand about some of the reactions that take place inside the cell. However, even without having done advanced research in chemistry it is possible to achieve a good basic understanding of how these different chemistries work, what the more complex reaction mean, and what happens inside a lithium-ion cell when you use energy from it.

The word “battery” comes from the Old French word baterie, meaning “action of beating,” relating to a group of cannons in battle. In the endeavor to find an energy storage device, scientists in the 1700s adopted the term “battery” to represent multiple electrochemical cells connected together.

The battery consists of two electrodes that are isolated by a separator and soaked in electrolyte to promote the movement of ions. New active materials are being tried, each offering unique attributes but none delivering an ultimate solution.

Improvements have been slow. Whereas Moore’s Law* doubled the number of transistors in an integrated circuit every two years, capacity gain of lithium-ion (Li-ion) has been about 8 percent per year in the decades following its introduction in 1991.

A lithium-ion battery (sometimes Li-ion battery or LIB) is a member of a family of rechargeable battery types in which lithium ions move from the negative electrode to the positive electrode during discharge and back when charging. Li-ion batteries use an intercalated lithium compound as one electrode material, compared to the metallic lithium used in a non-rechargeable lithium battery. The electrolyte, which allows for ionic movement, and the two electrodes are the constituent components of a lithium-ion battery cell.

Lithium-ion batteries are common in consumer electronics. They are one of the most popular types of rechargeable batteries for portable electronics, with a high energy density, small memory effect, and only a slow loss of charge when not in use. Beyond consumer electronics, LIBs are also growing in popularity for military, battery electric vehicle and aerospace applications. For example, lithium-ion batteries are becoming a common replacement for the lead acid batteries that have been used historically for golf carts and utility vehicles. Instead of heavy lead plates and acid electrolyte, the trend is to use lightweight lithium-ion battery packs that can provide the same voltage as lead-acid batteries, so no modification to the vehicle's drive system is required.

Chemistry, performance, cost and safety characteristics vary across LIB types. Handheld electronics mostly use LIBs based on lithium cobalt oxide (LiCoO2), which offers high energy density, but presents safety risks, especially whe damaged. Lithium iron phosphate (LiFePO4), lithium manganese oxide (LMnO or LMO) and lithium nickel manganese cobalt oxide (LiNiMnCoO2 or NMC) offer lower energy density, but longer lives and inherent safety. Such batteries are widely used for electric tools, medical equipment and other roles. NMC in particular is a leading contender for automotive applications. Lithium nickel cobalt aluminum oxide (LiNiCoAlO2 or NCA) and lithium titanate (Li4Ti5O12 or LTO) are specialty designs aimed at particular niche roles. The new lithium sulphur batteries promise the highest performance to weight ratio.

Lithium-ion batteries can be dangerous under some conditions and can pose a safety hazard since they contain, unlike other rechargeable batteries, a flammable electrolyte and are also kept pressurized. Because of this the testing standards for these batteries are more stringent than those for acid-electrolyte batteries, requiring both a broader range of test conditions and additional battery-specific tests. This is in response to reported accidents and failures, and there have been battery-related recalls by some companies.

Although the word "battery" is a common term to describe an electrochemical storage system, international industry standards differentiate between a "cell" and a "battery". A "cell" is a basic electrochemical unit that contains the basic components, such as electrodes, separator, and electrolyte. In the case of lithium-ion cells, this is the single cylindrical, prismatic or pouch unit that provides an average potential difference at its terminals of 3.7 V for LiCoO2 and 3.3 V for LiFePO4. A "battery" or "battery pack" is a collection of cells or cell assemblies which are ready for use, as it contains an appropriate housing, electrical interconnections, and possibly electronics to control and protect the cells from failure.

In this regard, the simplest "battery" is a single cell with perhaps a small electronic circuit for protection.

In many cases, distinguishing between "cell" and "battery" is not important. However, this should be done when dealing with specific applications, for example, battery electric vehicles, where "battery" may indicate a high voltage system of 400 V, and not a single cell.

The term "module" is often used as an intermediate topology, with the understanding that a battery pack is made of modules, and modules are composed of individual cells. Lithium batteries were proposed by M. S. Whittingham, now at Binghamton University, while working for Exxon in the 1970s.[16]Whittingham used titanium(IV) sulfide and lithium metal as the electrodes. However, this rechargeable lithium battery could never be made practical. Titanium disulfide was a poor choice, since it has to be synthesized under completely sealed conditions. This is extremely expensive (~$1000 per kilo for titanium disulfide raw material in 1970s). When exposed to air, titanium disulphide reacts to form hydrogen sulphide compounds, which have an unpleasant odour. For this, and other reasons, Exxon discontinued development of Whittingham's lithium-titanium disulfide battery.

COST ESTIMATION

Plant Capacity                                     50 Nos/Day

Land & Building (4080 sq.mt.)    US$ 5.18 Lac

Plant & Machinery                               US$ 6.23 Lac

Working Capital for 1 Month         US$ 6.84 Lac

Total Capital Investment                     US$ 18.97 Lac

Rate of Return                                      59%

Break Even Point                                 38%

• INTRODUCTION
  
• LITHIUM-ION BATTERY COMPONENTS, FUNCTIONS, AND MAIN MATERIALS
• LITHIUM-ION BATTERY CELL, MODULE AND PACK
• TECHNOLOGY AND COST CHALLENGES
• PRODUCTION STRUCTURE OF THE LITHIUM-ION BATTERY INDUSTRY
• FOUR MAJOR TYPES OF CATHODES FOR LITHIUM-ION BATTERIES: ENERGY DENSITY, PROS AND CONS, AND MANUFACTURERS
• MATERIALS USED AS LITHIUM SALTS:
• ORGANIC SOLVENTS:
• MATERIALS USED TO CREATE GEL ELECTROLYTE (FOR LITHIUM POLYMER BATTERY)
• STRUCTURE OF A STACK LITHIUM-ION BATTERY
• VALUE CHAIN OF LITHIUM-ION BATTERIES FOR VEHICLES
• GLOBAL VALUE CHAIN OF LITHIUM-ION BATTERIES FOR VEHICLES, WITH MAJOR 
•    GLOBAL PLAYERS AND U.S. PLAYERS WITH CURRENT AND PLANNED FACILITIES 
•     (NOT EXHAUSTIVE)
• ALLIANCES AND JOINT VENTURES BETWEEN BATTERY FIRMS AND AUTOMAKERS
• LITHIUM-BASED BATTERIES: ADVANTAGES AND CHALLENGES
• PERFORMANCE AND LIFE
• STATUS OF LITHIUM-ION HIGH-ENERGY/MEDIUM-POWER CELL AND BATTERY
•    TECHNOLOGIES
• STATUS OF LITHIUM-ION HIGH-POWER/MEDIUM-ENERGY CELL AND BATTERY
•    TECHNOLOGIES
• DEVELOPERS OF LITHIUM-ION TECHNOLOGY CELLS FOR HEV APPLICATIONS
• INTERNATIONAL STANDARDS FOR THE BATTERY INDUSTRY
• HIGH-POWER LITHIUM-ION BATTERY DESIGN
• GOLD PEAK INDUSTRIES NORTH AMERICA
• A 123 26650 LITHIUM-ION SPECIFICATIONS
• KOKAM AMERICA
• ELECTRO ENERGY, MOBILE PRODUCTS, INC., BI-POLAR LITHIUM-ION BATTERY
•    TECHNOLOGY
• SAFT HIGH-POWER LITHIUM-ION CELLS (VL20P)
• HIGH-POWER TOYOTA 12-A•H CELL LITHIUM-ION BATTERY
• CURRENT STATUS: TECHNOLOGY CHARACTERISTICS
• LITHIUM-ION BATTERY STATUS VS GOALS FOR POWER-ASSIST HEV
• ELECTRIC AND HYBRID VEHICLE BATTERY REQUIREMENTS (MODULE BASIS)
• USES AND APPLICATION
• FOR LI ION BATTERY
• FOR LI POLYMER BATTERY
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART FOR CELL MANUFACTURING
• PROCESS FLOW CHART FOR BATTERY ASSEMBLING
• MANUFACTURING PROCESS OF LITHIUM ION BATTERY
• MATERIAL PREPARATION AND MIXING
• (2) COATING AND DRYING
• CALENDARING
• SEPARATION AND DRYING
• (5) PACKAGE ASSEMBLY
• (6) CONTACTING, HOUSING, AND FILLING WITH ELECTROLYTE
• (7) FORMING AND AGING PROCESS
• (8) AMBIENT CONDITIONS FOR BATTERY PRODUCTION
• (9) TESTING PROCESS
• (A) THERMAL PERFORMANCE TESTS –
• (B) COLD START TESTS –
• (C) CAPACITY TESTS –
• (D) PULSE POWER TESTS –
• (E) SELF-DISCHARGE TESTS –
• (F) ENERGY EFFICIENCY TESTS –
• (G) CYCLIC LIFE TESTS-
• (H) CALENDAR LIFE TESTS –
• (I) REFERENCE PERFORMANCE TESTS –
• TYPES OF BATTERY CELLS
• CYLINDRICAL CELL
• CROSS SECTION OF A LITHIUM-ION CYLINDRICAL CELL
• POPULAR 18650 LITHIUM-ION CELL
• BUTTON CELL
• BUTTON CELLS PROVIDES SMALL SIZE, MOST ARE PRIMARY FOR SINGLE-CELL USE.
• PRISMATIC CELL
• CROSS SECTION OF A PRISMATIC CELL.
• POUCH CELL
• THE POUCH CELL
• SWOLLEN POUCH CELL
• PRICE COMPARISON OF LI-ION CELL TYPES
• ASSEMBLING PROCESS OF LITHIUM ION BATTERY
• (1) CELL SELECTION
• (2) CELL HANDLING
• (3) CELL STORAGE
• (4) ASSEMBLING
• (A) ASSEMBLING PROCESS OF CYLINDRICAL CELL BASED BATTERY PACK
• (I) CELL LEVEL ASSEMBLING:
• (II) ASSEMBLING PROCESS OF MODULE AND PACK LEVEL
• (B) ASSEMBLING PROCESS OF POUCH CELL BASED BATTERY PACK
• (I) ASSEMBLING PROCESS OF CELL LEVEL
• (II) ASSEMBLING PROCESS OF MODULE AND PACK LEVEL
• (C) ASSEMBLING PROCESS OF PRISMATIC CELL BASED BATTERY PACK
• (I) ASSEMBLING PROCESS OF CELL LEVEL
• (II) ASSEMBLING PROCESS OF MODULE AND PACK LEVEL
• JOINING TECHNOLOGY
• (A) ULTRASONIC WELDING OR ULTRASONIC METAL WELDING (UMW)
• (B) RESISTANCE SPOT/PROJECTION WELDING
• (C) MICRO-TIG OR PULSED ARC WELDING (PAW)
• (D) ULTRASONIC WEDGE BONDING
• (E) MICRO-CLINCHING
• (F) SOLDERING
• (G) LASER WELDING
• (H) MAGNETIC PULSE WELDING (MPW)/ELECTROMAGNETIC PULSE 
•     TECHNOLOGY (EMPT)
• (I) MECHANICAL ASSEMBLY
• (5) TESTING
• (6) BATTERY PACKAGING
• MODULE PACKING
• BATTERY RETENSION SYSTEM
• BATTERY TRAY
• (3) BATTERY MANAGEMENT SYSTEM
• (4) COOLING SYSTEM
• PLANT AND MACHINERY EQUIPMENT FOR CELL MANUFACTURING
• MIXING MACHINE
• GENERAL SPECIFICATION
• TECHNICAL SPECIFICATION
• COATING MACHINE
• AUTO SINGLE COATING MACHINE
• AUTO DOUBLE COATING MACHINE
• SLITTING MACHINE
• GENERAL SPECIFICATION
• TECHNICAL SPECIFICATION
• ROLL PRESS MACHINE
• GENERAL SPECIFICATION
• TECHNICAL SPECIFICATION
• WINDING MACHINE
• ELECTROLYTE FILLING MACHINE
• EQUIPMENTS FOR ASSEMBLY
• 1. LINEAR WORKPIECE CARRIER TRANSFER SYSTEM
• 2. PRE-ASSEMBLY STATION
• 3. AUTOMATIC MODULE ASSEMBLY STATION
• ASSEMBLY OF SECOND SIDE PLATE
• AUTOMATIC LINE CHANGE
• AUTOMATIC LASER WELDING STATION
• MARKET POSITION
• INDIA LITHIUM-ION BATTERY MARKET 2018-2023:
• 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
• INDIA LITHIUM-ION BATTERIES MARKET FORECAST AND OPPORTUNITIES, 2020
• INDIA LITHIUM-ION BATTERY MARKET MAJOR PLAYERS:
• INDIGENIZATION OF LITHIUM-ION BATTERY MANUFACTURING:
• A TECHNO-ECONOMIC FEASIBILITY ASSESSMENT
• LIB DEMAND IN INDIA: PROJECTIONS FOR 2030
• ECONOMICS OF LIB MANUFACTURING: 50 GWH PLANT
• ANALYSIS & RECOMMENDATIONS
• BATTERY MARKET POSITION
• 2. 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
• MANUFACTURERS/SUPPLIERS
• OF LI ION CELL AND LITHIUM POLYMER CELL
• MANUFACTURERS/SUPPLIERS OF LITHIUM ION BATTERY PACK
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF COPPER FOIL
• SUPPLIERS OF ALUMINIUM FOIL
• SUPPLIERS OF GRAPHITE POWDER
• SUPPLIERS OF LITHIUM IRON PHOSPHATE
• SUPPLIERS OF POLY ETHYLINE OXIDE
• SUPPLIERS OF POLY VINYAL DI FLORIDE
• SUPPLIERS OF CARBON BLACK
• SUPPLIERS OF N-METHYAL PYROLIDENE (NMP)
• SUPPLIERS OF PLANT AND MACHINERIES
• INDIAN SUPPLIERS OF CELL MAKING MACHINE
• SPOT WELDING MACHINE
• SUPPLIERS OF CHINA
• SUPPLIERS OF POWER TRANSFORMERS
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF ELECTRIC MOTOR
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSORS
• SUPPLIERS OF PLATFORM WEIGHING MACHINE
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
• SUPPLIERS OF JIGS AND FIXTURE
• SUPPLIERS OF SUBMERSIBLE WATER PUMP
• PRODUCT PHOTOGRAPHS

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)