Detailed Project Report on lithium-ion battery pack
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LITHIUM-ION BATTERY PACK
[CODE NO.3723]
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.
COST ESTIMATION
Plant Capacity 2000 Nos/Day
Land & Building (2500 sq.mt.) Rs. 2.65 Cr
Plant & Machinery Rs. 3.27 Cr
Working Capital for 2 Months Rs. 1778.54 Cr
Total Capital Investment Rs. 1784.80 Cr
Rate of Return 69%
Break Even Point 16%
INTRODUCTION
LITHIUM IRON PHOSPHATE (LIFEPO4)
LITHIUM ION CATHODE CHEMISTRY COMPARISON (USED
WITH CARBON ANODES)
CONSTRUCTION OF LI FERO 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) BATTERY CELL
(A) INSPECTION AND TESTING PROCESS OF CELL
(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 –
(A) CELL SELECTION
(B) CELL HANDLING PROCEDURE
(C) CELL STORAGE
(2) BATTERY PACKAGING
MODULE PACKING
BATTERY RETENSION SYSTEM
BATTERY TRAY
(3) BATTERY MANAGEMENT SYSTEM
(4) COOLING SYSTEM
(5) TESTING
(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
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/POSITION
GLOBAL CONTEXT AND IMPACT
OVERVIEW OF GLOBAL LIB MARKETS AND SUPPLY CHAIN
LITHIUM-‐ION BATTERY INTRODUCTION
PRISMATIC LIB CELL SCHEMATIC
CYLINDRICAL LIB CELL SCHEMATIC
SIMPLIfiED AUTOMOTIVE LIB MANUFACTURING VALUE CHAIN
LIB CONfiGURATIONS VARY SIGNIfiCANTLY ACROSS AUTO APPLICATIONS
CONSUMER ELECTRONICS REPRESENT THE MAJORITY OF DEMAND FOR LIBS
SIGNIfiCANT OVERCAPACITY IN THE AUTOMOTIVE LIB SUPPLY CHAIN
MODERATE TO STRONG DEMAND GROWTH FORECASTED
FOR AUTOMOTIVE LIBS
MODERATE SALES GROWTH IS FORECASTED FOR ELECTRIC
AND HYBRID VEHICLES
AUTOMOTIVE LIB PACK MARKETS EXPECTED TO REACH $14.3B BY 2020
LIB MARKET AND SUPPLY CHAIN SUMMARY
LIB CELL PRODUCTION PROCESS: CATHODE AND ANODE SHEETS
LIB CELL PRODUCTION PROCESS: STACKED POUCH CELL ASSEMBLY
NON - COST FACTORS DRIVE SOME LIB FACTORY LOCATION DECISIONS
QUALITATIVE FACTORS INflUENCING FACTORY LOCATION DECISIONS
MARKET OUTLOOK
PROJECTED MARKET DEMAND FOR LITHIUM-ION BATTERIES USED IN ELECTRIC VEHICLES FROM 2017 TO 2030 (IN GIGAWATT HOURS)
INDIA LITHIUM-ION BATTERY MARKET:
LITHIUM-ION BATTERY MARKET: SIZE AND DEMAND FORECAST IN USD BILLION, BY APPLICATION, INDIA, 2017- 2023
GLOBAL LITHIUM ION BATTERY MARKET EXPECTED
TO REACH $100,433.7 MILLION BY 2025
KEY FINDINGS OF THE LITHIUM ION BATTERY MARKET:
THE FUTURE OF BATTERY PRODUCTION OF ELECTRIC VECHICLE
PLANT LAYOUT
SUPPLIERS OF LI ION BATTERY PACK
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF LI ION CELL
(CHINA SUPPLIERS FOR LITHUM ION CELL AND BATTERY)
(INDIAN SUPPLIERS)
SUPPLIERS OF PLANT AND MACHINERY FOR LI ION BATTERY ASSEMBLY
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)
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