Project Report On Lithium Ion Battery Manufacturing Unit

LITHIUM ION BATTERY MANUFACTURING UNIT
[EIRI/EDPR/4023] J.C.: 2153XL
INTRODUCTION
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
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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).
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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.
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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.
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CONTENTS
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
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(8) FORMING AND AGING PROCESS
(9) AMBIENT CONDITIONS FOR BATTERY 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 –
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
BATTERIES AND BATTERY MODULE(S) SHALL BE SUBJECT OF THE
FOLLOWING TESTS:
(6) BATTERY PACKAGING
MODULE PACKING
BATTERY RETENSION SYSTEM
BATTERY TRAY
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(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
ROLL PRESS MACHINE
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
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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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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%
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Project Report On Lithium Ion Battery Manufacturing Unit

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What are the two main types of lithium batteries?

What are some advantages of lithium-ion batteries?

LITHIUM ION BATTERY MANUFACTURING UNIT

[EIRI/EDPR/4023] J.C.: 2153XL

Lithium batteries are mainly of two types:

(A) Lithium-Metal Batteries

(B) Lithium-Ion Batteries

Lithium-ion (Li-ion) batteries , also known as secondary batteries, are

Lighter Design: Li-ion batteries are lighter as compared to other rechargeable

Quick charging: Lithium-ion batteries take lesser time to charge as compared to

Low maintenance: Li-ion batteries do not require maintenance to ensure their

(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

01. PLANT ECONOMICS

Plant Capacity 4000 KWH/Day

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