determination of process-structure-performance...
TRANSCRIPT
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Determination of Process-Structure-Performance Correlations
and Development of Alternative Production Processes
by the German Cell-Production Research Cluster “ProZell”
Arno Kwade and Henrike Bockholt
Institute for Particle Technology and Battery LabFactory, TU Braunschweig
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Battery Cell Production, Demand and Utilization
2013 2014 2015 20160
20
40
60
80
100
120 entire capacity (max)
entire capacity (min)
entire utilization (max) [%]
entire utilization (min) [%]
[GW
h]
0
20
40
60
80
100
120
[%]
According to: Fraunhofer Institute for Systems and Innovation Research ISI
Global Cell Production Capacities (2013 to 2016)
Existing cell factories are
fully utilized
+
Strong increasing
demand of battery cells,
prediction of up to
400 GWh/a in 2025
Continuous increase of
manufacturing capacity is
required to satisfy the
demand and avoid
bottlenecks
Demand
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Ele
ctr
od
e
pro
du
cti
on
Cell
pro
du
cti
on
Cell
Co
nd
itio
nin
g
Materialpre-treatment
and mixing
coating and
dryingcalendering
cutting and
drying
package
formingcontacting
housing and
sealing
electrolyte
fillingformation and
aging
electrochemical
quality checkCells
Process Chain of Cell Manufacturing
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Calculation Model for Cell Production
Influencing Factors
cell
parameters
production
parameters
economical
parameters
Calculation Model
calculation with
combined input
Results
factory design
cost planning
J.-H. Schünemann, Volkswagen VARTA Microbattery,
A. Kwade, TU Braunschweig, Vortrag Kraftwerk Batterie 2014
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Cost of a Battery Cell
J.-H. Schünemann – Modell zur Bew ertung der Herstellkosten von
Lithiumionenbatteriezellen, Dissertation, iPAT Schriftenreihe, Sierke-Verlag
Manufacturing
Cost
188,96 €/kWh
Material Cost
dominated by
exogenic factors
Production Cost
accessible
cost potential
Other*
4,43 €/kWh
2,3 %
Material
135,98 €/kWh
72,0 %
Direct Labor
22,09 €/kWh
11,7 %
Depreciation
15,56 €/kWh
8,2 %
Capital
5,20 €/kWh
2,8 %
Energy
5,70 €/kWh
3,0 %
* maintenance, insurance, imputed area rent
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Electrode and Cell Production@ Battery LabFactory Braunschweig
Facts and Figures
▪ Battery research since 2008
▪ 7 institutes of TU BS and
PTB
▪ 900 m² pilot processing area
(+ 500 m2 laboratories)
▪ 160 m² dry room
▪ approx. 50 researchers and
technicians
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Research Strategy of BMBF and BMWiBattery Research Germany
Economically Attractive Lithium-Ion Battery Cells
with Excellent Performance
Material Science
Electrochemistry
Process Engineering
Production Engineering
Batterie 2020
ProZellApplication-related
Technologies
6. Energie-forschungsprogramm
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Competence Cluster for Battery Cell Production (ProZell)Members
11 research projects
1 accompanying project
22 research institutes
12 locations
(5 Institutes)
(4 Institutes)
(4 Institutes)
sponsored by
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Competence Cluster for Battery Cell Production (ProZell)Aims
Superior Aim:
Long-term, holistic and profound scientific basis for
erection and sustainable further development of an
international competitive battery cell production in
Germany and Europe
Process
x
Inter-
mediate x
Process
y
Battery
Cell
Intermediate
PropertiesCost Cost
Process-Cost-Function of Battery Cell
Process-Quality-Property-Function of Battery Cell
Holistic
Understanding
Of Battery
Cell Production
sponsored by
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Research Aims of ProZell Projectswith specific focus on one particular process step
Coating Dry Coating Drying
Assembling FormationDispersing Drying Calendering
Electrolyte Filling
KonSuhl – continuous slurry processing
MultiDis – multiscale simulation of slurry processing
LoCoTroP – low-cost dry coating
ProKal – modelling the calendering process
Roll-it – R2R intensive drying
Cell-Fi – process optimization
for efficient electrolyte filling
OptiZellForm – energetic
optimization of formation
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Research Aims of ProZell Projectswith a more holistic view on the manufacturing
QS-Zell – QA methods in the
production of large-format LIB-cells
Sim2Pro – multi-level simulation
of process-product-interactionsHighEnergy – high-capacity structured electrodes
HiLo – processes and electrode
structures for high-load cathodes
Coating Dry Coating Drying Electrolyte Filling
Assembling FormationDispersing Drying Calendering
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Cluster Objectives Slurry Processing
Continuous processing of
battery slurries by extrusion
▪ Enhancing the efficiency in
production
▪ Reducing the mixing and
dispersing time (dwell time
~ 3 - 6 min)
▪ Possibility to decrease
dryer length
Prediction of carbon black destructuring in
planetary mixers of different geometry
▪ Simulation on different scales (particle scale
and machine scale)
▪ Structure characterization
▪ Decease of Carbon Black usage
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Cluster Objectives Electrode Production
Development of thick and multilayered electrodes
▪ Reducing the amount of inactive cell materials
(current collector e.g.) to enhance energy density
▪ Enhancing binders, particle size distributions, use
of material blends
▪ Decreasing material- and production costs
▪ Electrode structure optimization by simulation tools
to ensure maximum transport performance
T. Danner et al. J Power Sources, 334, 191–201 (2016)
Source: ZSW, Ulm
Dry and water based coating of
battery electrodes
▪ Massive cost reduction, especially
energy and solvent usage
▪ Mixing and structuring of materials
▪ Electrostatically enhanced spray
coating, also multilayer deposition
Source: IPA, Stuttgart
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Cluster Objectives Electrode Finishing
Defined porosity- und structure-
adjustment by defined calandering
▪ Enhancing energy- and power-density
and life time expectation by prediction of
favourable calandering parameters
▪ Increasing the operability of calendaring
machines by dynamic machine model
Roll to roll condinuous IR dryer
▪ Fast heat and solvent transport
▪ Short drying times and controlled
remaining solvent content
▪ Prevention of water reuptakeSource: ZSW, Ulm
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Cluster projects „HighEnergy“Design and production of high-load electrodes
Integrated slitting and stacking of
thick electrodes
▪ Decreasing failures and
enhancing quality
▪ Increasing production rate
▪ Decreasing costs and production
failures
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Cluster Objectives Cell Finishing
Accelerating, homogenization and
inline process control of electrolyte
filling
▪ Decrease of filling time and costs
▪ Simulation of wetting processes
during cell filling
▪ Effect of separator and cell design
Accelarating formation and decreasing aging
time
▪ Systematic approach to optimize formation
routines
▪ Investigation of chemical and electrochemical
parameters
▪ Effect of production parameters on formation
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Cluster project „Sim2Pro“Simulation of cell production chain
Frame for process simulation
and performance prediction
▪ Coupling process models to
calculate production rates,
energy and labour demand etc.
▪ Effect of processes on cell
performance
Quality assurance in lithium ion
battery cell production
▪ Investigating of crucial process
steps for cell quality
▪ Development and investigation
of new measurement methods
and overall quality assurance
concepts
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Connection of the individual projects of the clusterSystematic cooperation
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acatech – DEUTSCHE AKADEMIE DER TECHNIKWISSENSCHA FTEN, 2016
ProZell
provides
knowledge for
today´s and
future cell
factories
Competence Cluster for Battery Cell Production (ProZell)Networking with Industry
sponsored byElectrode Production
Assembly Activation
Further Processing
Module:Dispersing
Module:Coating &
Drying
Module:Calendering
Module:Coil Handling
Module:Cutting
Module:Contacting
Module:Stacking
Module:Packaging
Module:Drying
Module:Electrolyte
Filling
Module:Formation
Module:Aging
Process Step X
Standardized
Interface
Research Platformfor
Industrial Production
Giga Factory
Pilot plant
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Conclusions
▪ ProZell will provide detailed knowledge
about cell production processes and their
costs
▪ Detailed process knowledge will help to
strengthen the existing German medium-
sized cell manufacturers and to establish a
mass cell production in Europe both in
intermediate- and long-term
▪ Many other fields for use of battery cells
are known beside electro mobility
EAS Germany GmbH 2016
w ww.litarion.com/litarion_litacell_cells.html
liacon-batteries.de/
Stationary
storage
from Liacon
Batteries
Battery cell from
Electrovaya-Litarion
Battery cells
from EAS in
fieldCoinPower from
Varta Microbatteries
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Acknowledgements