Industry Overview
Lithium batteries are widely used to power electrical and electronic devices such as laptop computers, mobile phones, power tools, telecommunication systems, and electric cars and vehicles. Lithium batteries are broadly classified into lithium-metal batteries and lithium-ion batteries. Lithium-metal batteries are generally primary batteries and are not rechargeable, while lithium-ion batteries are rechargeable and are commonly used in portable electronics and electric mobility applications.
Lithium-ion batteries operate through the movement of lithium ions between the positive and negative electrodes. During charging, lithium ions move from the positive electrode to the negative electrode through the electrolyte, while electrons travel through the external circuit. When the battery is fully charged, the movement of ions stops. During discharge, lithium ions move back toward the positive electrode through the electrolyte, while electrons travel through the external circuit to supply electrical power to the connected device.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 72.33 Nos/Day |
| Land & Building (2000 sq.mt.) | Rs. 3.31 Cr |
| Plant & Machinery | Rs. 88 Lac |
| Working Capital for 2 Months | Rs. 82.07 Cr |
| Total Capital Investment | Rs. 86.60 Cr |
| Rate of Return | 28% |
| Break Even Point | 35% |
Content Index
- INTRODUCTION
- LITHIUM BATTERIES ARE MAINLY OF TWO TYPES:
- WORKING
- TYPES OF LI BATTERIES
- (A) LITHIUM-METAL BATTERIES
- (B) LITHIUM-ION BATTERIES
- ADVANTAGES
- DISADVANTAGES
- CONSTRUCTION MATERIAL
- COMPOSITION OF LITHIUM-ION BATTERIES
- CATHODE
- ANODE
- ELECTROLYTE
- SEPARATOR
- CATHODE MATERIALS
- ANODE MATERIALS
- ELECTROLYTES
- SEPARATORS
- DIFFERENT SHAPES OF LITHIUM-BATTERIES
- USES AND APPLICATION
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- ASSEMBLING PROCESS OF LITHIUM ION BATTERY
- (1) BATTERY CELL
- (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)
- ADVANTAGES
- (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
- 4. ASSEMBLY OF SECOND SIDE PLATE
- 5. AUTOMATIC LINE CHANGE
- 6. AUTOMATIC LASER WELDING STATION
- MARKET SURVEY
- INDIA LITHIUM-ION BATTERY MARKET 2018-2023
- INDIA LITHIUM-ION BATTERY MARKET
- DECREASING COST OF LITHIUM-ION BATTERIES - TO SUPPLEMENT THE DEMAND
- RENEWABLE-BASED ENERGY STORAGE - OPPORTUNITY FOR GROWTH
- ELECTRIC VEHICLES & LITHIUM ION BATTERY MARKET
- CHANGING LANDSCAPE OF THE ENERGY SECTOR, INDIA, 2017-2030
- KEY TARGET AUDIENCE:
- INDIGENISATION OF LITHIUM-ION BATTERY MANUFACTURING:
- GLOBAL LIB PRODUCTION AND PRICE TREND
- LIB DEMAND IN INDIA: PROJECTIONS FOR 2030
- ECONOMICS OF LIB MANUFACTURING: 50 GWH PLANT
- RESULTS
- ANALYSIS & RECOMMENDATIONS
- POLICY INTERVENTIONS
- PLANT LAYOUT
- PRESENT MANUFACTURERS/SUPPLIERS FOR LI-OIN BATTERY ASSEMBLY PLANT FOR AUTOS, E-VEHICLES AND UPS SYSTEMS
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF LI-ION CELL
- 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
- 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)
Frequently Asked Questions
The two main types discussed in the report are lithium-metal batteries and lithium-ion batteries. Lithium-metal batteries are generally primary batteries and are not rechargeable, whereas lithium-ion batteries are rechargeable. Lithium-ion technology is widely used in portable electronic devices, power tools, telecommunication systems, electric vehicles, and other energy applications. The report further examines lithium-ion battery construction, materials, cell formats, assembly methods, battery management systems, cooling systems, testing, and joining technologies used in battery pack assembly.
A lithium-ion battery works by moving lithium ions between its positive and negative electrodes through an electrolyte. During charging, lithium ions move toward the negative electrode while electrons travel through the external circuit. During discharge, the ions move back toward the positive electrode and electrons flow through the external circuit, providing electrical power. The report describes this charge-discharge mechanism along with the roles of the cathode, anode, electrolyte, and separator in lithium-ion battery construction.
The main electrochemical components are the cathode, anode, electrolyte, and separator. These components work together to enable controlled movement of lithium ions and electrons during charging and discharging. Battery packs also incorporate structural and electronic systems such as cells, modules, battery management systems, cooling systems, trays, and retention systems. The report separately discusses cathode materials, anode materials, electrolytes, separators, construction materials, and different lithium-battery shapes.
The report covers cylindrical, pouch, and prismatic cell formats for lithium-ion battery pack assembly. Each format requires appropriate cell-level and module- or pack-level assembly procedures. The report describes cell selection, handling and storage, followed by packaging, module packing, battery retention, battery trays, battery management systems, cooling systems, and testing. The choice of cell format influences the mechanical design and assembly approach of the resulting battery pack.
Lithium-ion battery assembly can use several joining technologies depending on the cell and pack design. The report covers ultrasonic welding, resistance spot or projection welding, micro-TIG or pulsed arc welding, ultrasonic wedge bonding, micro-clinching, soldering, laser welding, magnetic pulse welding, and mechanical assembly. These technologies are used to establish reliable electrical and mechanical connections while supporting the required manufacturing process and battery-pack configuration.
A lithium-ion battery assembly plant can include equipment for material transfer, pre-assembly, module assembly, plate assembly, line changes, and laser welding. The report specifically identifies a linear workpiece carrier transfer system, pre-assembly station, automatic module assembly station, assembly of the second side plate, automatic line change, and automatic laser welding station. It also addresses supporting equipment and suppliers for electrical panels, air compressors, material handling, fire fighting, air conditioning, air pollution control, and water pumping systems.
Lithium-ion batteries are used across consumer electronics, power tools, telecommunication systems, electric vehicles, and energy-storage applications. The report examines the Indian lithium-ion battery market, electric vehicles, renewable-based energy storage, and the changing energy sector. It also considers lithium-ion battery assembly plants serving automobiles, electric vehicles, and UPS systems, along with market demand, manufacturing economics, supply requirements, plant layout, and the role of indigenous battery manufacturing.
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