ASSEMBLY LINES FOR BOTH LFP PRISMATIC
AND NMC CYLINDRICAL CELLS
[CODE NO.4319]
Battery Pack: Energy storage device, which is comprised one or more cells or modules electrically connected together inside a mechanical pack with electronics as required for safety and operation.
The battery pack may incorporate a protective housing and be provided with terminals or other interconnection arrangement. It may include protective devices and control and monitoring required for safe and proper operation. A typical example of a battery pack may be built by using 6s2p Lithium-ion module. It may provide detailed information (e.g., cell voltage, temperature, capacity) to a higher level battery system management device.
Battery management system or unit (BMS, BMU): Electronic system associated with a battery which monitors and/or manages its state, calculates secondary data, reports that data and/or controls its environment to influence the battery's performance and service life and has the functions to cut off in case of abnormal conditions (e.g., over charging, over current and overheating and charge balancing between cells or parallel cells blocks).
Depending on the application and its size, the function of the BMS/BMU can be assigned to the battery cell, module, string, pack or system and equipment using the battery. A common implementation is a BMS/BMU made of several electronic modules located at different levels of the system.
A battery management system (BMS) is sometimes also referred to as a battery management unit (BMU).
Battery System: System which incorporates one or more battery cells, modules, strings or battery packs and has one or more BMS or BMU. The battery system is generally defined for high power and capacity batteries made of several battery strings or packs of blocks or modules it may include cooling or heating units and gas exhaust arrangement.
Lithium Ion Battery Cells
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.
Characteristics of lithium ion battery cells
The lithium ion battery cells have the following main characteristics:
? High gravimetric and volumetric energy density
? Higher voltage than aqueous technologies (> 2V)
? No memory effect and negative effect of partial state of charge (PSoC)
? Moderate environmental impact depending on chemical composition and features (less cobalt, less toxic electrolyte, better recycling.)
? High rate discharge
? Fast charge and long life cycle
? Safety
? Wide temperature ranges
Some advantages of Li-ion batteries are:
1. High specific energy and high load capabilities;
2. Long cycle and extend shelf-life
3. Maintenance-free;
4. High capacity, low internal resistance, good coulombic efficiency
5. Simple charge algorithm and reasonably short charge times;
6. Low self-disch
However, their limitations are:
1. Circuit protection requirement to prevent thermal run-away if stressed
2. Degradation at high temperatures and when stored at high voltage;
3. No rapid charge possible at freezing temperatures
COST ESTIMATION
Plant Capacity 200 Nos/Day
Land & Building (3000 sq.mt.) Rs. 2.90 Cr
Plant & Machinery Rs. 5.75 Cr
Working Capital for 2 Months Rs. 37.06 Cr
Total Capital Investment Rs. 45.98 Cr
Rate of Return 42%
Break Even Point 32%
INTRODUCTION
LITHIUM ION BATTERY CELLS
CHARACTERISTICS OF LITHIUM ION BATTERY CELLS
SOME ADVANTAGES OF LI-ION BATTERIES ARE:
HOWEVER, THEIR LIMITATIONS ARE:
TYPES OF LITHIUM-ION BATTERIES
1. LITHIUM COBALT OXIDE
2. LITHIUM MANGANESE OXIDE
3. LITHIUM IRON PHOSPHATE (LFP)
4. LITHIUM NICKEL MANGANESE COBALT OXIDE (NMC)
5. LITHIUM NICKEL COBALT ALUMINUM OXIDE
6. LITHIUM TITANATE
7. LITHIUM NICKEL MANGANESE COBALT OXIDE (NMC)
LITHIUM IRON PHOSPHATE (LFP)
SHAPES OF LIB CELL
CYLINDRICAL CELL
FIGURE 1: CROSS SECTION OF A LITHIUM-ION CYLINDRICAL CELL
FIGURE 2: POPULAR 18650 LITHIUM-IONS CELL
FIGURE 3: DEMAND AND SUPPLY OF THE 18650
BUTTON CELL
FIGURE 4: BUTTON CELLS PROVIDES SMALL SIZE, MOST ARE PRIMARY FOR SINGLE-CELL USE
PRISMATIC CELL
FIGURE 5: CROSS SECTION OF A PRISMATIC CELL
POUCH CELL
FIGURE 6: THE POUCH CELL
FIGURE 7: SWOLLEN POUCH CELL
FIGURE 8: PRICE OF LI-ION ($US/WH)
FIGURE 9: PRICE COMPARISON OF LI-ION CELL TYPES
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
CELL SORTING:
MODULE ASSEMBLY:
PACK ASSEMBLY:
FINAL TESTING AND STORAGE:
EQUIPMENTS FOR AUTOMATIC ASSEMBLY
1. LINEAR WORKPIECE CARRIER TRANSFER SYSTEM
2. PRE-ASSEMBLY STATION
3. AUTOMATIC MODULE ASSEMBLY STATION
4. ASSEMBLY OF SECOND SIDE PLATE
5. AUTOMATIC LINE CHANGE
6. AUTOMATIC LASER WELDING STATION
MARKET POSITION
INDIA LITHIUM-ION BATTERY MARKET
DECREASING COST OF LITHIUM-ION BATTERIES - TO SUPPLEMENT THE DEMAND
RENEWABLE-BASED ENERGY STORAGE - OPPORTUNITY FOR GROWTH
CHANGING LANDSCAPE OF THE ENERGY SECTOR, INDIA, 2017-2030
INDIA LITHIUM-ION BATTERY MARKET MAJOR PLAYERS:
INDIGENIZATION OF LITHIUM-ION BATTERY MANUFACTURING
ECONOMICS OF LIB MANUFACTURING: 50 GWH PLANT
ANALYSIS & RECOMMENDATIONS
BATTERY MARKET POSITION
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
PRINCIPLES OF PLANT LAYOUT
STORAGE LAYOUT:
EQUIPMENT LAYOUT:
SAFETY:
PLANT EXPANSION:
FLOOR SPACE:
UTILITIES SERVICING:
BUILDING:
MATERIAL-HANDLING EQUIPMENT:
RAILROADS AND ROADS:
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
PLANT LAYOUT
SUPPLIERS OF LIB BATTERY PACK
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF LIB CELL
INDIAN SUPPLIERS
SUPPLIERS OF PLANT AND MACHINERY
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)
