Detailed Project Report on lithium ion battery manufacturing unit

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LITHIUM ION BATTERY MANUFACTURING UNIT

[CODE NO.4023]

Lithium batteries are now powering a wide range of electrical and electronical devices, including laptop computers, mobile phones, power tools, telecommunication systems and new generations of electric cars and vehicles.

Lithium batteries are mainly of two types:

Lithium metal batteries and lithium ion batteries. Basically, the difference between them is that lithium metal batteries are those that are not rechargeable, thus, primary, and lithium ion batteries are those that can be recharged. As an example, your laptop or cell phone is likely to have a lithium ion battery, whereas your watch may have a lithium metal battery

TYPES OF LI BATTERIES

(A) Lithium-Metal Batteries

Lithium-metal batteries are known as primary batteries and are usually non-rechargeable. They contain metallic lithium and feature higher charge densities (longer life) than other non-rechargeable batteries (e.g. alkaline or zinc-carbon). The most common type of lithium batteries use metallic lithium as anode, manganese dioxide as cathode and a salt of lithium dissolved in an organic solvent, usually composed of a mixture of a high-permittivity (e.g. propylene carbonate) and a low-viscosity solvent(e.g.dimethoxyethane).

Having a longer life, lithium-metal batteries can replace ordinary alkaline batteries in many consumer devices, such as calculators, pacemakers, remote car locks, cameras or watches.

(B) Lithium-Ion Batteries

On the basis of chemistry used for ions carrying electrolyte material, Lithium battery can be classified into Lithium ion and lithium Polymer. Lithium ion battery uses liquid lithium ion as electrolyte while lithium polymer use solid or gelatin like polymers as electrolyte.Lithium ion batteries have high energy density and cost less than lithium polymer

Lithium-ion (Li-ion) batteries , also known as secondary batteries, are rechargeable batteries in which lithium ions move from the negative electrode, usually made of carbon, to the positive electrode made of a metal oxide (nickel, manganese and cobalt) during discharge, and back when charging. The electrolyte is typically a mixture of organic solvents, such as ethylene carbonate, dimethyl carbonate or diethyl carbonate, containing complexes of lithium ions, such as lithium hexafluorophosphate (LiPF6), Lithium hexafluoroarsenate monohydrate (LiAsF6), lithium perchlorate (LiClO4), lithium tetrafluoroborate (LiBF4) or lithium triflate (LiCF3SO3).

Li-ion batteries have high energy density, tiny memory effect and low self-discharge. They are commonly found in home and portable electronics (e.g. laptop computers). They are also growing in popularity for battery electric vehicles or aerospace applications and are becoming a common replacement for many applications that have been using historically lead acid batteries.

Advantage

Lighter Design: Li-ion batteries are lighter as compared to other rechargeable batteries considering the battery capacity and are thus used in portable consumer electronic devices where weight and form factor are the important selling points.

High energy density: Li-ion batteries have a higher energy density when compared to other rechargeable batteries. Li-ion Batteries have high power capacity without being too bulky. Lithium ion batteries are thus used in electronic equipment like mobile phones and laptops, which need to operate longer between charges while consuming more power and need batteries with a much higher energy density. Additionally, electric vehicles also run on Li-ion batteries.

Low self-discharge and longer shelf life: Li-ion battery has lower self-discharge rate as compared to other rechargeable batteries, about 1.5 percent per month which enables longer shelf life when not in use as it discharges slowly than other rechargeable batteries.

Lower memory effect: Memory effect refers to as the process of losing maximum energy capacity of rechargeable batteries due to repeated recharges after being only partially discharged. Li-ion battery has a minimal memory effect, while other rechargeable batteries like nickel-metal hydride have a very high memory effect.

Quick charging: Lithium-ion batteries take lesser time to charge as compared to other rechargeable batteries like lead acid, nickel-metal hydride, and nickel- cadmium.

Longer lifespan: Li-ion batteries have a longer life span as compared to others. Some lithium ion batteries lose 30 percent of their capacity after 1000 cycles while advanced lithium ion batteries have better capacity even after 5000 cycles.

Low maintenance: Li-ion batteries do not require maintenance to ensure their performance at optimal level.

High open-circuit voltage: Li-ion batteries exhibit higher open-circuit voltage due to their chemistry when compared to other batteries such as lead acid, nickel-metal hydride, and nickel-cadmium.

Disadvantages

(I) Circuit protection requirement to prevent thermal run-away if stressed;

(II) Degradation at high temperatures and when stored at high voltage;

(III) No rapid charge possible at freezing temperatures

(IV) Severe transportation regulations required when shipping in larger quantities.

Li-ion is a generic term used to cover several types of battery chemistries and several formats for various applications. Each of them has their own pros and cons.

COST ESTIMATION

Plant Capacity 4000 KWH/Day

Land & Building (8000 sq.mt.) Rs. 2.99 Cr

Plant & Machinery Rs. 1.76 Cr

Working Capital for 2 Months Rs. 93 Cr

Total Capital Investment Rs. 98.17 Cr

Rate of Return 74%

Break Even Point 20%

INTRODUCTION

LITHIUM BATTERIES ARE MAINLY OF TWO TYPES:

TYPES OF LI BATTERIES

(A) LITHIUM-METAL BATTERIES

(B) LITHIUM-ION BATTERIES

ADVANTAGE

DISADVANTAGES

CONSTRUCTION MATERIAL

COMPOSITION OF LITHIUM-ION BATTERIES

CATHODE

ANODE

ELECTROLYTE

SEPARATOR

CATHODE MATERIALS

ANODE MATERIALS

ELECTROLYTES

SEPARATORS

DIFFERENT SHAPES OF LITHIUM-BATTERIES

LITHIUM-POLYMER BATTERIES

I) HIGH ENERGY DENSITY –

II) FLAT VOLTAGE CURVE –

III) NO MEMORY EFFECT –

IV) LOW SELF DISCHARGE –

LITHIUM POLYMER ADVANTAGES

LITHIUM POLYMER LIMITATIONS

CONSTRUCTION

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

(1) MATERIAL PREPARATION AND MIXING

(2) COATING AND DRYING

(3) CALENDARING

(4) SEPARATION AND DRYING

(5) PACKAGE ASSEMBLY

(6) CONTACTING, HOUSING, AND FILLING WITH ELECTROLYTE

(8) FORMING AND AGING PROCESS

(9) AMBIENT CONDITIONS FOR BATTERY PRODUCTION

(10) TESTING PROCESS

(A) THERMAL PERFORMANCE TESTS –

(B) COLD START 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 –

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

(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

(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

BATTERIES AND BATTERY MODULE(S) SHALL BE SUBJECT OF THE FOLLOWING TESTS:

(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

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

A. ASSEMBLY OF SECOND SIDE PLATE

B. AUTOMATIC LINE CHANGE

C. AUTOMATIC LASER WELDING STATION

MARKET POSITION

FIGURE 1: LCE PRODUCTION FORECAST FOR DIFFERENT APPLICATIONS

FIGURE 2: LI-ION BATTERY PRICE TREND IN RECENT YEARS

TABLE 1: LIB DEMAND IN EV AND GRID SECTORS BY 2030

TABLE 2: ASSUMPTIONS FOR ESTIMATING THE LIB MANUFACTURING COST IN INDIA

FIGURE 3: SHARE OF VARIOUS COMPONENTS IN COST OF INDIGENOUS LIB BATTERY

FIGURE 4: IMPACT OF CAPITAL AND PRODUCTION SUBSIDY ON MANUFACTURING

COST OF LIBS IN INDIA

PLANT LAYOUT

SUPPLIERS OF LI ION CELL AND LITHIUM POLYMER CELL

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-METHYL PYRROLIDENE (NMP)

SUPPLIERS OF PLANT AND MACHINERY

INDIAN SUPPLIERS OF CELLL MAKING MACHINE

SUPPLIERS OF SPOT WELDING MACHINE

SUPPLIERS OF CHINA

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRIC MOTOR

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF COOLING TOWER

SUPPLIERS OF EFFULENT 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

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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