Detailed Project Report (DPR) on assembly lines for both lfp prismatic and nmc cylindrical cells

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)