LITHIUM POLYMER BATTERY (POUCH CELL) MANUFACTURING PLANT (CAP: 560 NOS/DAY)
[EIRI/EDPR/4499] J.C.: 2715XL
INTRODUCTION
A lithium polymer battery, or more correctly lithium-ion polymer battery (abbreviated as LiPo, LIP, Li-poly, lithium-poly and others), is a rechargeable battery of lithium-ion technology using a polymer electrolyte instead of a liquid electrolyte. High conductivity semisolid (gel) polymers form this electrolyte. These batteries provide higher specific energy than other lithium battery types and are used in applications where weight is a critical feature, such as mobile devices, radio-controlled aircraft and some electric vehicles.
A lithium-polymer battery, or more correctly lithium-ion polymer battery (abbreviated variously as LiPo, LIP or Li-pol) is a Li-ion battery in which the electrolyte has been "plasticized" or "gelled" through a polymer additive. Even with the gelled electrolyte added, a LiPo battery is essentially the same as a Li-ion battery. Both systems use identical cathode and anode material and contain a similar amount of electrolyte. LiPo batteries usually come in a soft package or pouch format, which makes them lighter and less rigid. LiPo batteries offer slightly higher specific energy and can be made thinner than conventional Li-ion batteries.
Li-polymer cells, also known as soft or pouch cells have a thin and somewhat ‘soft’ housing – like a pouch – made from deep-drawn aluminum foil. The mostly prismatic housing can be produced more easily and cheaply than the hard cases of Li-ion cells. The other components, in wafer-thin layer foils (< 100 µm) can also be mass-produced at relatively low cost. The cells are lightweight, thin and can be made in a wide range of shapes and sizes. Both large formats and heights of less than 1 mm can be achieved. The cells do, however, require careful mechanical handling.
COST ESTIMATION
Plant Capacity 560 NOS/Day
Land & Building (3000 sq.mt.) Rs. 17.24 Cr
Plant & Machinery Rs. 1.74 Cr
Working Capital for 2 Months Rs. 4.44 Cr
Total Capital Investment Rs. 23.85 Cr
Rate of Return 51%
Break Even Point 34%
CONTENTS
INTRODUCTION
ELECTRODE SET:
MERITS OF LITHIUM-POLY BATTERY:
COMPONENTS OF LI-POLYMER CELL
THE FOUR COMPONENTS OF LI-ION BATTERY
(1) CATHODE
(2) ANODES
(3) ELECTROLYTES
(4) SEPARATOR
3. VERSATILE IN NATURE – LITHIUM-ION BATTERY VS LITHIUM POLYMER BATTERY
4. LOW SELF-DISCHARGE LEVEL – LITHIUM-ION BATTERY VS LITHIUM POLYMER BATTERY
5. THIN WITH HUGE CAPACITY – LITHIUM-ION BATTERY VS LITHIUM POLYMER BATTERY
DEMERITS OF LITHIUM-POLYMER BATTERY
1. HEAVILY PRICED
2. ENERGY DENSITY
3. SHORTER LIFE SPAN
DEMERITS OF LIPOLY CELL
POUCH CELL
MAIN ADVANTAGES:
MAIN DISADVANTAGES:
POUCH CELL LIMITATIONS IN BATTERY PACK ASSEMBLY
EASY ACCESS TO THE TABS WHEN MAKING CONNECTIONS
MECHANICAL DAMAGE DUE TO SWELLING
VOLUMETRIC ENERGY DIMINISHED BY HEAT TRANSFER PLATES
USES AND APPLICATION
APPLICATIONS
LITHIUM POLYMER BATTERY IN AGRICULTURE
LITHIUM POLYMER BATTERY IN AUTOMOTIVE EQUIPMENT
LITHIUM POLYMER BATTERY IN COMMUNICATION
LITHIUM POLYMER BATTERY IN CONSUMER
LITHIUM POLYMER BATTERY IN INDUSTRIAL
LITHIUM POLYMER BATTERY IN MEDICAL
LITHIUM POLYMER BATTERY IN METERING
B.I.S. SPECIFICATION
PROCESS FLOW CHART FOR LI POL POUCH CELL MANUFACTURING
FOR PRODUCTION
FOR ASSEMBLING
MANUFACTURING PROCESS POUCH CELL
(1) MATERIAL PREPARATION AND MIXING
PREPARING THE ELECTRODES
ELECTRODE SHEETS CONTAIN THE FOLLOWING INGREDIENTS:
(2) COATING AND DRYING
(3) CALENDERING
(4) SEPARATION AND DRYING
(5) PACKAGE ASSEMBLY
COMBINING ELECTRODES
PUMPING ELECTROLYTE INTO THE CELL
POLYMER ELECTROLYTES
ASSEMBLING THE POUCH CELL
(6) CONTACTING, HOUSING, AND FILLING WITH ELECTROLYTE
(8) FORMING AND AGING PROCESS –
(9) AMBIENT CONDITIONS FOR CELL 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 –
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
1. ASSEMBLY OF SECOND SIDE PLATE
2. AUTOMATIC LINE CHANGE
3. AUTOMATIC LASER WELDING STATION
MARKET OVERVIEW
MAJOR MARKET PLAYERS
SUPPLIERS OF LIPO POUCH 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 ETHYLENE OXIDE
SUPPLIERS OF POLYVINYL DIFLUORIDE
SUPPLIERS OF CARBON BLACK
SUPPLIERS OF N-METHYL PYRROLIDONE (NMP)
INDIAN SUPPLIERS OF COMPELETE LIFEPO4 CELL PRODUCTION LINE
SUPPLIERS OF SPOT WELDING MACHINE
SUPPLIERS OF CHINA
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP)
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
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