Lithium Polymer Battery (Pouch Cell) Manufacturing Plant (Cap: 560 Nos/Day)

LITHIUM POLYMER BATTERY (POUCH CELL) MANUFACTURING PLANT (CAP: 560 NOS/DAY)

[EIRI/EDPR/4499] J.C.: 2715XL

INTRODUCTION

A lithium polymer battery, or more correctly lithium-ion polymer battery (abbreviated as LiPo, LIP, Li-poly, lithium-poly and others), is a rechargeable battery of lithium-ion technology using a polymer electrolyte instead of a liquid electrolyte. High conductivity semisolid (gel) polymers form this electrolyte. These batteries provide higher specific energy than other lithium battery types and are used in applications where weight is a critical feature, such as mobile devices, radio-controlled aircraft and some electric vehicles.

A lithium-polymer battery, or more correctly lithium-ion polymer battery (abbreviated variously as LiPo, LIP or Li-pol) is a Li-ion battery in which the electrolyte has been "plasticized" or "gelled" through a polymer additive. Even with the gelled electrolyte added, a LiPo battery is essentially the same as a Li-ion battery. Both systems use identical cathode and anode material and contain a similar amount of electrolyte. LiPo batteries usually come in a soft package or pouch format, which makes them lighter and less rigid. LiPo batteries offer slightly higher specific energy and can be made thinner than conventional Li-ion batteries.

Li-polymer cells, also known as soft or pouch cells have a thin and somewhat ‘soft’ housing – like a pouch – made from deep-drawn aluminum foil. The mostly prismatic housing can be produced more easily and cheaply than the hard cases of Li-ion cells. The other components, in wafer-thin layer foils (< 100 µm) can also be mass-produced at relatively low cost. The cells are lightweight, thin and can be made in a wide range of shapes and sizes. Both large formats and heights of less than 1 mm can be achieved. The cells do, however, require careful mechanical handling.

COST ESTIMATION

Plant Capacity            560 NOS/Day  

Land & Building (3000 sq.mt.)    Rs. 17.24 Cr    

Plant & Machinery                    Rs. 1.74 Cr 

Working Capital for 2 Months    Rs. 4.44 Cr 

Total Capital Investment          Rs. 23.85 Cr 

Rate of Return                          51%

Break Even Point                      34%

CONTENTS

INTRODUCTION

ELECTRODE SET:

MERITS OF LITHIUM-POLY BATTERY:

COMPONENTS OF LI-POLYMER CELL

THE FOUR COMPONENTS OF LI-ION BATTERY

(1) CATHODE

(2) ANODES

(3) ELECTROLYTES

(4) SEPARATOR

3. VERSATILE IN NATURE – LITHIUM-ION BATTERY VS LITHIUM POLYMER BATTERY

4. LOW SELF-DISCHARGE LEVEL – LITHIUM-ION BATTERY VS LITHIUM POLYMER BATTERY

5. THIN WITH HUGE CAPACITY – LITHIUM-ION BATTERY VS LITHIUM POLYMER BATTERY

DEMERITS OF LITHIUM-POLYMER BATTERY

1. HEAVILY PRICED

2. ENERGY DENSITY

3. SHORTER LIFE SPAN

DEMERITS OF LIPOLY CELL

POUCH CELL

MAIN ADVANTAGES:

MAIN DISADVANTAGES:

POUCH CELL LIMITATIONS IN BATTERY PACK ASSEMBLY

EASY ACCESS TO THE TABS WHEN MAKING CONNECTIONS

MECHANICAL DAMAGE DUE TO SWELLING

VOLUMETRIC ENERGY DIMINISHED BY HEAT TRANSFER PLATES

USES AND APPLICATION

APPLICATIONS

LITHIUM POLYMER BATTERY IN AGRICULTURE

LITHIUM POLYMER BATTERY IN AUTOMOTIVE EQUIPMENT

LITHIUM POLYMER BATTERY IN COMMUNICATION

LITHIUM POLYMER BATTERY IN CONSUMER

LITHIUM POLYMER BATTERY IN INDUSTRIAL

LITHIUM POLYMER BATTERY IN MEDICAL

LITHIUM POLYMER BATTERY IN METERING

B.I.S. SPECIFICATION

PROCESS FLOW CHART FOR LI POL POUCH CELL MANUFACTURING

FOR PRODUCTION

FOR ASSEMBLING

MANUFACTURING PROCESS POUCH CELL

(1) MATERIAL PREPARATION AND MIXING

PREPARING THE ELECTRODES

ELECTRODE SHEETS CONTAIN THE FOLLOWING INGREDIENTS:

(2) COATING AND DRYING

(3) CALENDERING

(4) SEPARATION AND DRYING

(5) PACKAGE ASSEMBLY

COMBINING ELECTRODES

PUMPING ELECTROLYTE INTO THE CELL

POLYMER ELECTROLYTES

ASSEMBLING THE POUCH CELL

(6) CONTACTING, HOUSING, AND FILLING WITH ELECTROLYTE

(8) FORMING AND AGING PROCESS –

(9) AMBIENT CONDITIONS FOR CELL PRODUCTION

(10) 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 –

PLANT AND MACHINERY

EQUIPMENT FOR CELL MANUFACTURING

MIXING MACHINE

GENERAL SPECIFICATION

TECHNICAL SPECIFICATION

COATING MACHINE

AUTO SINGLE COATING MACHINE

AUTO DOUBLE COATING MACHINE

SLITING 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

1. ASSEMBLY OF SECOND SIDE PLATE

2. AUTOMATIC LINE CHANGE

3. AUTOMATIC LASER WELDING STATION

MARKET OVERVIEW

MAJOR MARKET PLAYERS

SUPPLIERS OF LIPO POUCH 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 ETHYLENE OXIDE

SUPPLIERS OF POLYVINYL DIFLUORIDE

SUPPLIERS OF CARBON BLACK

SUPPLIERS OF N-METHYL PYRROLIDONE (NMP)

INDIAN SUPPLIERS OF COMPELETE LIFEPO4 CELL PRODUCTION LINE

SUPPLIERS OF SPOT WELDING MACHINE

SUPPLIERS OF CHINA

SUPPLIERS OF POWER TRANSFORMER

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

SUPPLIERS OF COOLING TOWER

SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP)

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

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