Complete Technology Hand Book on Lithium Ion and Lead-Acid Batteries Manufacturing and its Recycling

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Batteries have quietly woven themselves into the fabric of our modern lives, powering our smartphones, laptops, electric vehicles, and a myriad of portable devices that have become indispensable. As we stand on the cusp of an era where clean and sustainable energy solutions are imperative, batteries have taken center stage, promising to revolutionize the way we store and use energy. It is within this transformative landscape that this comprehensive handbook, "Complete Technology Handbook on Lithium Ion and Lead-Acid Batteries Manufacturing and Its Recycling," finds its purpose.
The story of batteries is a fascinating journey that has evolved over centuries, with each advancement bringing us closer to the dream of efficient, eco-friendly energy storage. This book, presented through a detailed and carefully structured series of chapters, is designed to take you on this journey. It explores the principles of operation, the inner workings of lithium-ion and lead-acid batteries, and the chemistry behind their functionality. It also delves into the design considerations, manufacturing processes, and end-user applications that have become essential aspects of the battery industry.
One of the striking features of this handbook is its commitment to embracing the full spectrum of battery technology, from the sturdy and trusted lead-acid batteries that have served us for generations to the cutting-edge lithium-ion batteries that are poised to redefine the way we harness energy. Understanding the past and present is essential to shaping the future, and we provide insights into the developments, trends, and limitations of both these battery technologies.
Moreover, the book ventures into the world of recycling, a topic of growing significance in a world that is increasingly concerned with sustainability. As the demand for batteries continues to rise, so too does the importance of recycling and managing the environmental impact of used batteries. The handbook discusses various recycling methods and technologies, ensuring that this aspect of battery production is not overlooked.
In a rapidly changing technological landscape, it is crucial to have access to accurate and comprehensive information. This handbook not only serves as a reference guide for industry professionals and manufacturers but also extends its reach to budding entrepreneurs and students eager to explore the potentials of the battery manufacturing sector. Whether you aim to start your battery business or simply wish to gain a deeper understanding of the batteries that power your daily life, this book offers valuable insights into the intricacies of battery design, production, and recycling.
To achieve this comprehensive scope, the book draws upon the expertise of various contributors, including industry experts and professionals who have dedicated their careers to the field of battery technology. It also benefits from the vast resources and knowledge available in the public domain, making it a one-stop resource for all your battery-related queries.
In an age where technology is driving innovation at an unprecedented pace, this handbook aims to be a beacon of knowledge, a guide to understanding the very core of the devices that keep our world connected and powered. We invite you to embark on this enlightening journey through the pages of "Complete Technology Handbook on Lithium Ion and Lead-Acid Batteries Manufacturing and Its Recycling," and we hope it serves as a valuable resource in your quest to unravel the secrets of battery technology.
The book contains chapters on Introduction, Battery Design and Function, Industrial Battery Outlook, Future Scope of Lithium Ion Batteries, Future of Lithium-Ion Batteries And Electrification, Lithium Ion Battery, Lithium-Ion Battery Applications, Lithium Battery Manufacturing, Recycling of Lithium-ion Batteries, Aluminium-air Battery, Alkaline Batteries, Metal-Air Battery, Lead-Acid Batteries, Lead-Acid Batteries: Fundamentals, Technologies, and Applications, Lead-Acid Battery Manufacturing Equipment, Lead-Acid Battery Recycling, Zinc-Carbon Battery, International Standards and Testing Applicable to Batteries, Battery Smelting and Lead Refining, Dry Lead Acid Battery, Lithium Ferro Phosphate Battery, Lithium Ion Battery Container, Lithium-Ion Batteries Manufacturing Unit, Pouch Cell Manufacturing Plant, Recycle of Lead Acid Battery, Secondary Lithium Ion Manufacturing (Lithium Ion Battery Pack), Solar Lead Acid Battery.
ISBN: 9788189765071
Chapter 1
Introduction
- Principles of Operation
- How Lead Acid Battery works
- Chemical Action During Discharging
- Chemical Action During Recharging
- Primary batteries
- Zinc–manganese dioxide systems
- Zinc–mercuric oxide battery
- Zinc–silver oxide battery
- Lithium batteries
- Air-depolarized batteries
- Other primary battery systems
- Storage batteries
- Lead-acid batteries
- Alkaline storage batteries
- Lithium storage batteries
- Development of batteries
- Contents-cum-Index
Chapter 2
Battery Design and Function
- Lithium Ion Battery Electrochemistry and Function
- Functions
- Electrochemistry behind rechargeable lithium ion batteries
- Charge and discharge
- Considerations in selection of Cathode, Anode and Electrolyte
- Anode material should exhibit the following properties
- Cathode material should exhibit the following properties
- Electrolytes should exhibit the following properties
- Cylindrical vs Prismatic Cell Design Tradeoffs
- Battery Module Design Approach
- Modular circuit board
- Safety Considerations
- Best Practices for lithium-ion Cell/Battery Use
- Transporting batteries
- Charging/Discharging
- Storage
Chapter 3
Industrial Battery Outlook
- Market dynamic – global lead acid battery market
- Lead acid battery market segmental overview
- Rapid technological advancements and expansion in the telecom sector to boost market growth
- Lead Acid Battery Market Segment Insights
- Lead Acid Battery Product Insights
- Lead Acid Battery Construction Method Insights
- Lead Acid Battery End-User Insights
- The Lead-Acid Segment Expected to Dominate the Market
- Lead acid battery market by technology
- Lead acid battery market by end user
- Lead acid battery market by construction method
- Lead acid battery market by type
- Lead acid battery market by industrial
- Lead acid battery market by geography
- Lead acid battery market key players
- Asia Pacific Lithium Ion Battery Market Overview
- Asia Pacific Lithium Ion Battery Market Segmentation
- Regional Market Outlook
- High Cost of Li-ion Batteries-Major Challenge
- Covered in this Asia Pacific lithium ion battery market report
- Key Market Players
Chapter 4
Future Scope of Lithium Ion Batteries
- Five key performance characteristics of battery technology evolution
- Key battery technology Performance characteristics
- Present Day Lithium Ion Batteries
- Deficiencies of Present Lithium Ion Batteries and Likely Improvements
- Li-Ion Batteries are Amazing Energy Storage Devices
- The Future of Li-Ion Energy Storage
- A Finite Resource
- Early Li-Ion Battery Development
- Benefits of a Lithium Ion Battery
- Importance of Lithium Ion Batteries at Hiden Analytical
Chapter 5
Future of Lithium-Ion Batteries and Electrification
- Major Trends
- Future Trends in Battery Technology
- NanoBolt lithium tungsten batteries
- Zinc-manganese oxide batteries
- Organosilicon electrolyte batteries
- Gold nanowire gel electrolyte batteries
- TankTwo String Cell™ batteries
Chapter 6
Lithium Ion Battery
- Characteristics of lithium-ion batteries
- How do lithium-ion batteries produce electricity?
- Advantages
- Benefits of lithium-ion batteries
- Classification
- Lithium Cobalt Oxide
- Lithium Manganese Oxide
- Lithium Iron Phosphate (LFP)
- Lithium Nickel Manganese Cobalt Oxide (NMC)
- Lithium Nickel Cobalt Aluminum Oxide
- Lithium Titanate
- Chemistry
- Cathode Materials
- Electrolyte
- Cells Couples and Reaction Mechanisms
- Characteristics of lithium primary batteries
- Summary of Design and Performance Characteristics
- Soluble-Cathode Lithium Primary Batteries
- Solid-Cathode Lithium Primary Cells
- Safety and handling of lithium batteries
- Factors Affecting Safety and Handling
- Safety Considerations
- Lithium/Sulfur Dioxide (Li/SO2) Batteries
- Chemistry
- Construction
- Performance
- Voltage
- Cell and Battery Types and Sizes
- Alkaline Batteries
- Coin Cell Batteries
- What is a Secondary Cell?
- Lead-acid Batteries
- Ni-Cd Battery
- Ni-MH Battery
- Li-ion Battery
- Li-Po battery
- Use and Handling of Li/SO2 Cells and Batteries-Safety Considerations
- Applications
- Lithium/Thionyl Chloride (Li/SOCl2) Batteries
- Chemistry
- Advantages of Li-SOCl2
- Usage of Lithium Thionyl Chloride Batteries
- Lisocl2 Bobbin Battery
- Elecorev Battery Has Long Storage Lifetime
- Specifications
- Spirally Wound Cylindrical Batteries
- Increasing the Plate Area
- Characteristics of a Spiral Wound Battery
- Flat or Disk-Type Li/SOCl2 Cells
- Large Prismatic Li/SOCl2 Cells
Chapter 7
Lithium-Ion Battery Applications
- Applications of Li-Ion Batteries
- Automotive Applications for the Lithium-Ion Batteries
- Starting Lighting Ignition
- Idle Stop
- Full Hybrid
- Mild Hybrid
- Microhybrid electric vehicles
- Hybrid electric vehicles
- Plug-in hybrid electric vehicle and range extended electric vehicle
- Electric Vehicle
- Plug-in Hybrid Electric Vehicle
- Public Transportation
- Robotics and Autonomous Applications
- Features
- Industrial Applications
- Marine and Maritime Applications
- Grid and Stationary Applications
- Bulk Energy Storage
- Ancillary Services
- Customer Energy Management Services
- Li-ion Battery for Numerous Applications
- Future of Li-Ion Batteries
Chapter 8
Lithium Battery Manufacturing
- Electrode Coating
- Cell Assembly
- Prismatic Cells
- Cylindrical Cells
- Terminal Welding
- Challenges
- Canning or Enclosing
- Challenges
- Filling
- Challenges
- Formation
- Process Control
- Support Services
- Challenges
- Ageing
- Challenges
- Final Control Checks
- Lithium ion Battery Pack Assembly Line Making Machine
- Battery Cell Tester
- Types of Battery Tester
- Automatic Li-ion Battery Pack Production Line
- Technical Specification
- Machine Features
- Battery Production Information Management System
- Automatic Battery Cell Sorting Machine for Cylindrical Lithium Battery
- Features
- Spot Welding Machine for Lithium Ion battery
- Product Specification
- Product Description
- Integrated Tester
- Performance Characteristics:
- Charging and Discharging Aging Testing Machine
- Function Features
Chapter 9
Recycling of Lithiumion Batteries
- Repairing and Remanufacturing
- Mechanical processing
- Hydrometallurgical processing
- Repairing and Remanufacturing
- Raw Materials
- Technical Process
- Technical Standards
- Remanufacturing
- Refurbishing
- Repurposing
- Energy storage system concept demonstration
- Second-Life Lithium Battery
- Overcoming obstacles
- Lithium-ion Battery Recycling - Process & Equipment
- Filter Press – Removal of the Black Mass
- Evaporation and Heated Tank System
- Filter Press – Removal of the Lithium Carbonate
- Filter Press Features
- Clarifier
- Sludge Dryer
- Thermal Evaporators
- Reverse Osmosis (RO)
- Ultrafiltration
- Atmospheric Evaporators
Chapter 10
Aluminium-air Battery
- Electrochemistry
- Materials and Methods
- Materials
- Hydrogen Evolution and Half-Cell Test
- Full-Cell Test
- Aluminium-air battery: discovery, commercial alloys and state of the art.
- Discovery and production
- Commercial aluminium alloys.
Chapter 11
Alkaline Batteries
- Advantages of Alkaline Battery
- Disadvantage of Alkaline Battery
- Construction of Alkaline Battery
- Chemistry in Batteries
- Electrochemistry
- Alkaline Battery Chemicals
- Temperature Effects on Performance
- Capacity
- Voltage
- Shelf Life
- Discharge types
- Constant resistance (B)
- Constant current (A)
- Constant power (W)
- Testing / Care / Warnings:
- Testing
- Care and Handling Do’s:
- Care and Handling Don’ts
- Warnings
- Design and Safety Considerations
- Current
- Recharging of alkaline batteries
- Leaks
- Disposal
- Uses of Alkaline Batteries
- Alkaline Battery Recycling Industry
- Improving efficiency and quality
- Production of other battery minerals
- Key process steps
- Key benefits
- How are Batteries Made?
- The Manufacturing Process
- The separator
- The anode
- The seals
- The label
- Quality Control
Chapter 12
Metal-Air Battery
- Lithium-air battery
- Aluminum-air battery
- Zinc-air battery
- Sodium-air battery
- Magnesium-air battery
- Potassium-air battery
- Iron-air battery
Chapter 13
Lead-Acid Batteries
- Introduction
- Construction
- Container
- Plates
- Active Component
- Separators
- Battery Edges
- Lead Acid Battery Working Principle
- Different Types
- Lead Acid Battery Chemical Reaction
- Life
- Lead Acid Battery Applications
- Battery Efficiency
- Lead Acid Battery Configurations
- Special Considerations for Lead Acid Batteries
- Boost Charging
- Specific Gravity (SG)
- Special Considerations for Gelled, Sealed Lead Acid Batteries
- Failure Modes for Lead Acid Batteries
- Installation
- Safety
- Maintenance
- Battery Disposal and Recycling
- Electrode Materials and Configuration
- Electrode Configuration
- Battery Housing
- Potential Problems with Lead Acid Batteries
- Corrosion of terminals
- Self-Discharge
- Change in form of materials
- Modifications to the electrolyte
- Electrolyte Volume and Concentration
- Captive Electrolyte Lead Acid Batteries
- Typical Commercially Available Battery Units
- Use Pattern of Lead-Acid Batteries
- Charge-Discharge Procedures of Lead-Acid Batterie
- Non-automobile applications of lead-acid batteries
- Stationary Applications of Lead-Acid Batteries
- Standby Applications of Lead-Acid Batteries
- Backup Power Applications of Lead-Acid Batteries
- Automobile applications of lead-acid batteries
- Automobile Starting-Lighting-Ignition Applications
- Electric and Hybrid Electric Vehicle Applications of Lead-Acid Batteries
Chapter 14
Lead-Acid Batteries: Fundamentals, Technologies, and Applications
- Introduction
- Materials and Properties
- Porosity, Pore Size, and Pore Shape
- Ionic Resistance
- Electrochemical Compatibility
- Acidic and Oxidation Stability
- Puncture Resistance
- Surface Area
- Separator Synthesis
- Polyethylene Separator
- Absorptive Glass Mat Separator
- Darak® Separator
- Rubber Separators
- Separator Structure Design and Fabrication
- Positive Ribs
- Negative Ribs
- Embossed/Corrugated
- Compression/Resiliency
- Fabrication
- Effects of material composition, morphology, and synthesis conditions on battery performance
- Antimony Poisoning and Water Loss
- Low Electrical Resistance
- Effect of battery operating conditions on separator performance
- Basic Condition/Extreme Shrinkage
- Hydration Shorts
- Extreme Oxidation
- Technical challenges, mitigation strategies, and perspectives
- High-Power Starter Batteries
- Deep-Cycle Batteries
Chapter 15
Lead-Acid Battery Manufacturing Equipment
- Grid Casting
- Grid Caster
- Strip Expansion Grid
- Continuous Grid Caster
- Lead Oxide Production
- Barton Pot Process
- Ball Mill Process
- Paste Mixing
- Batch Paste Mixer
- Continuous Paste Mixer
- Pasting
- Curing
- Formation
- Formation of Positive Plates
- Formation of Negative Plates
- Tank Formation
- Case Formation
- Battery Assembly
- Group Stacking
- Alignment
- Group Burning
- Group Alignment
- Group Insertion
- Inspection and Terminal Alignment
- Short Circuit Testing
- Intercell Welding
- Shear Testing
- Case Cover Sealing
- Leak Testing
- Terminal (Post) Burning
- Aluminum Foil Sealing
- Acid Filling
- Packing
- Quality assurance and control
Chapter 16
Lead-Acid Battery Recycling
- Battery Breaking
- Historical Background of Battery Breaking
- Modern Battery Breaking Process
- Battery Breaking: Potential Sources of Environmental Contamination
- Lead Reduction
- Pyrometallurgical Methods
- Hydrometallurgical Methods
- Lead Reduction: Potential Sources of Environmental Contamination
- Lead Refining
- Pyrometallurgical Refining
- Lead Refining: Potential Sources of Environmental Contamination
- Lead Battery Recycling Plant
- Lead Battery Recycling Process
- Scope
- Equipment for Setting Up Lead Battery Recycling Plant
- Battery Cutting Machines/Battery Breakers
- Breaking System & Separation of Components
- Battery Cutting and Punching Machine Benefits:
- Lead Rotary Furnace
- The Battery breaking floor Area
- Plastic Waste Storage Area
- Furnace Oil/LDO (if used) Storage
- Carbon Storage
- Smelting/Refining and Casting Area
- Cooling cum Settling Chambers
- Cyclone separators
- Bag Filters
- ID Fan
- Alkaline Scrubber
- Stack
- Effluent Treatment Plant (ETP)
- Hazardous waste Storage
- Product Lead Ingot Storage
- Choice of Smelting Furnace
- Refining Pots
- Lead Ingoting casting systems
Chapter 17
Zinc-Carbon Battery
- Characteristics
- Chemistry
- Construction
- Cylindrical Cell
- Carbon cathode
- Manganese dioxide
- Electrolyte
- Carbon rod
- Separator
- Seal
- Jacket
- Electrical contacts
- Inside Out Cylindrical Construction
- Flat Cell and Battery
- Voltage Rating of Zinc Carbon Battery
- Energy Density of Zinc Carbon Battery Cell
- Types of Zinc Carbon Battery
- Advantages and Disadvantages of Zinc Carbon Battery
- Advantages of Leclanche’ Battery
- Disadvantages of Leclanche’ Battery
- Advantages of Zinc Chloride Battery
- Disadvantages of Zinc Carbon Battery
Chapter 18
International Standards and Testing Applicable to Batteries
- International Safety Standards for Batteries
- General Battery Standards
- Lithium Battery Standards
- Nickel Metal Hydride Battery Standards
- Nickel Cadmium Battery Standards
- Lead Acid Battery Standards
- Photovoltaic Battery Standards
- Safety Standards
- STRD Low Voltage Directive
- Automotive Battery Standards
- Aircraft Battery Standards
- Military Standards for Batteries, Software, EMC/RFI, Safety & Quality
- Radio Battery Standards
- Standby Power Systems Standards
- Software Standards
- EMC/RFI Standards
- Ingress Protection (IP) Standards
- Battery Monitoring Standards
- Battery Recycling and Disposal Standards
- Other Related Electrical Standards
- Quality Standards
- CTIA Authorized Testing Laboratory (CATL)
- Lithium battery testing and certification
- Global battery safety standards and regulations
Chapter 19
Plant Economics on Battery Smelting and Lead Refining
- Introduction
- Battery Smelting and Refining Of Lead
- Process Flow Chart
- Manufacturing Process
- Scrap Pretreatment
- Smelting
- Refining
- Varta Process
- MA & CX Process
- Scrap Pretreatment
- Battery Breaking Process
- Battery Breaking
- Pollution Control Process
- Pollution Management Plan
- Lead Plant Pollution Control
- Furnace
- Settling Chamber
- Gravity Chamber/Cooling Tower
- Cyclone
- Bag House
- Stack
- Plant Economics
- Land & Building
- Plant & Machinery
- Fixed Capital
- Working Capital Requirement/Month
- Total Capital Investment
- Turn Over/Annum
Chapter 20
Plant Economics on Dry Lead Acid Battery
- Introduction
- Working Principle of Lead Acid Battery
- Construction and components of dry lead acid battery
- Construction
- Container
- Plates
- Active Component
- Separators
- Battery Edges
- Steps in battery manufacturing process
- Manufacturing Steps of Lead-Acid Batteries
- Oxide and Grid Production Process
- Pasting and Curing
- Assembling the Elements
- Filling and Formation
- Manufacturing Process in Details
- List of raw material
- Manufacturing Plastic Container and Cover
- Manufacturing Process of PVC/ABS Battery Container
- Plate Preparation
- Tubular Plate
- Manufacturing process of flat plate
- Lead Oxide Preparation
- Grid Casting:
- Paste Preparation
- Pasting Process
- Curing and Drying:
- Assembly
- Group stacking
- Group burning
- Group strapping
- Group insertion
- Heat sealing
- Post burning
- Leak testing
- Formation
- Cell packing:
- Acid filling:
- Testing of battery
- Static Battery Voltage Test
- Plant Economics
- Land & Building
- Plant & Machinery
- Fixed Capital
- Working Capital Requirement/Month
- Total Capital Investment
- Turn Over/Annum
Chapter 21
Plant Economics on Lithium Ferro Phosphate Battery
- Introduction
- Plant Economics
- Land & Building
- Plant & Machinery
- Fixed Capital
- Working Capital Requirement/Month
- Total Capital Investment
- Turn Over/Annum
Chapter 22
Plant Economics on Lithium Ion Battery Container
- Introduction
- Indigenization of Lithium-Ion Battery Manufacturing
- Plant Economics
- Land & Building
- Plant & Machinery
- Fixed Capital
- Working Capital Requirement/Month
- Total Capital Investment
- Turn Over/Annum
Chapter 23
Plant Economics on Lithium-Ion Batteries Manufacturing Unit
- Introduction
- Plant Economics
- Land & Building
- Plant & Machinery
- Fixed Capital
- Working Capital Requirement/Month
- Total Capital Investment
- Turn Over/Annum
Chapter 24
Plant Economics on Pouch Cell Manufacturing Plant
- Introduction
- Main advantages
- Main disadvantages
- Manufacturing Process Pouch Cell
- Material preparation and mixing
- Preparing the Electrodes
- Process Flow Chart for Li Pol Pouch Cell Manufacturing
- For Production
- For Assembling
- Coating and Drying
- Calendaring
- Separation and Drying
- Package assembly
- Combining Electrodes
- Pumping Electrolyte into the Cell
- Polymer Electrolytes
- Assembling the Pouch Cell
- Contacting, housing and filling with electrolyte
- Forming and Aging Process
- Ambient Conditions for Cell Production
- Testing Process
- Plant Economics
- Land & Building
- Plant & Machinery
- Fixed Capital
- Working Capital Requirement/Month
- Total Capital Investment
- Turn Over/Annum
Chapter 25
Plant Economics on Recycle of Lead Acid Battery
- Battery Life
- Raw Material
- Lead Battery Breaking and Separation
- Desulphurization System
- Lead Refining and Alloying
- Lead Casting
- Gas cleaning system
- Off-gas cleaning system of a lead recycling furnace
- Plant Economics
- Land & Building
- Plant & Machinery
- Fixed Capital
- Working Capital Requirement/Month
- Total Capital Investment
- Turn Over/Annum
Chapter 26
Plant Economics on Secondary Lithium Ion Manufacturing (Lithium Ion Battery Pack)
- Introduction
- Construction of LI Ferro Phosphate Battery
- Construction Material
- Composition of Lithium-ion Batteries
- Cathode
- Anode
- Electrolyte
- Separator
- Cathode Materials
- Anode Materials
- Electrolytes
- Separators
- Size of Lifepo4 Cylindrical Cell
- Manufacturing process of lithium ion battery
- Plant Economics
- Land & Building
- Plant & Machinery
- Fixed Capital
- Working Capital Requirement/Month
- Total Capital Investment
- Turn Over/Annum
Chapter 27
Plant Economics on Solar Lead Acid Battery
- Introduction
- Lead Acid Battery Plates
- Plante Plate
- Structure of Plante Plate
- Faure Plate
- Manufacturing Process
- Plant Economics
- Land & Building
- Plant & Machinery
- Fixed Capital
- Working Capital Requirement/Month
- Total Capital Investment
- Turn Over/Annum
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