advanced manufacturing processes for low cost … greenlion.pdf · fondation universitaire, rue...
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Joint EC / European Green Cars Initiative
Clustering Event 2012Fondation Universitaire, Rue d'Egmont 11, 1000 Bruxelles
11/12 July 2012
Advanced Manufacturing Processesfor Low Cost Greener Li-ion Batteries
GC.NMP.2011-1Project financially supported by 7th Framework Program of the European Commission under Grant Agreement no. 285268
GREENLIONAdvanced Manufacturing Processes for
Low Cost GREENer Li-ION BatteriesCall: FP7-2011-GC-ELECTROCHEMICAL-STORAGE
Topic: Advanced eco-design and manufacturing processes for batteries
and electrical components
Grant Agreement #285268
Total budget: 8.6 M€
EC contribution: 5.6 M€
Starting date: 1/11/11
Duration: 4 years
Electrode Cell Modulewith integrated
BMS
Batterypack
Actions at 3 key levels of the battery value chain:
i) more environmentally friendly production of
the battery componentsii) substantial shortening of the battery assembly
procedure
iii) easier and more effective disassembly and end-of-life
recycling
From green materials to greener batteries
GREENLION CONCEPT
i.Electrode Processing
- Aqueous Processing of Natural Binders(independent of active materials chemistry – starting selection: C/LFP)
Non-fluorinated polymers RECYC
COST
Laser cutting COST
Aqueous slurries WASTE/ ECO
Non-thermoplastic polymers COST
GREENLION
Improvements
Cell Assembly
- Slot-die coating process adjustment on pilot line
ii. Cell Assembly
Stack-Winding process COST
Eco-friendly bonding process
ECO
Adjusted formation step time
COST
Pre-drying for lower dry room
requirements COST
More efficient and long-life cell
sealing ECO
Laser cutting instead of die
notching COST
GREENLION
Improvements
iii. Module Design & Assembly
Module
Testing
Packaging &
Management
System
Module
Assembly
Automation of module assembly process
COST
Easy disassembling for maintenance
and recycling at their end of life ECO
Lighter battery module design through
air cooled solutions ECO/ COST
Pouch cells
Battery Pack
- Lighter module design through air cooled solutions:Electrical and thermal simulation of GREENLION cells to develop a module including BMS (SOC, SOH algorithms, equalization) and Thermal Management System.
- Eco-designed bonding techniques to improve sealing and disassembly:Degreasing and activation/primering of surfaces for structural bonding. Adhesives/glues with additives to activate easier disassembly for maintenance/reuse/recycling.
- 3D design of automatic battery module/pack assembly line:Pilot line in 3D (validation of a prototype for Key-Processes) as a turn-key production line for Li-ion module manufacturing (Cycle time: 3 sec/cell production capacity 880MWh/year)
GREENLION
Improvements
...through an step by step approach:
Electrode Cell Module
GEN1 GEN2 GEN3
Electrodes (0.5 m2, s.s.)Laboratory coater
Electrodes (m2, d.s)Industrial pilot plant coater
Cells (ca. 5 Ah) Cells (ca. 20 Ah)
Modules
GREENLION Consortium
16 partners from 7 member states:
• 10 Industries
(8 Large, 2 SME)
• 3 Research Institutes
• 3 Universities
MODULECELL
Materials Electrodes Manufacturing Design / Assembly
Specs. /Validation
GREENLION Partnership and RolesIN
DR
ES
Recycling / LCA
NOTE: atribution of roles to partners not exhaustive; here limited to only one mention per partner for clarity
WorkPackage structure
WP2 Advancedelectrode
development & testing
WP3Cell design,
development & testing
WP4Battery module
eco-design, assembly &
testing
WP7Demonstration of battery module &
validation
WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line
WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)
WP8 Dissemination, Exploitation & Training
MAIN ACHIEVEMENTS
SO FAR
WP2Advancedelectrode
development& testing
WP2 Advancedelectrode
development & testing
WP3Cell design,
development & testing
WP4Battery module
eco-design, assembly &
testing
WP7Demonstration of battery module &
validation
WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line
WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)
WP8 Dissemination, Exploitation & Training
2.1 Battery materials for aqueous coating
UL, POLIMI, SOLVAY, TIMCAL, WWU
2.2 Formulations and processes for aqueous coatings
WWU, ENEA, UL, SOLVAY, TIMCAL
2.3 Characterization and testing of electrodes
ENEA, WWU, POLIMI, VW
Selection of components
for GEN1 cells (≈ 5Ah):
Graphite / NMC
CMC binder
0.5 m2 negative and
positive electrodes for
GEN1 cell:
DELIVERED
WP3Cell design,
development & testing
WP2 Advancedelectrode
development & testing
WP3Cell design,
development & testing
WP4Battery module
eco-design, assembly &
testing
WP7Demonstration of battery module &
validation
WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line
WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)
WP8 Dissemination, Exploitation & Training
3.1 Cell specs & design
CEGASA, KEMET, WWU, ENEA, RESCOLL
3.2 Cell assembly process optimization
KEMET, CEGASA, RESCOLL, CIDETEC, WWU
3.3 - Cell testing procedure
AIT, CIDETEC, ENEA, WWU, VW, SEAT
3.4 - Testing and evaluation of Cells
ENEA, AIT, CIDETEC, WWU
3.5 – Cell simulation & modelling
AIT, CIDETEC
Design of the final
GREENLION cell (≈ 20Ah)
UNDERWAY Manufacture of GEN1 cells
from fluorine-free binders,
small area electrodes
ABOUT TO START
MAIN ACHIEVEMENTS
SO FAR
WP4Battery module
eco-design, assembly &
testing
WP2 Advancedelectrode
development & testing
WP3Cell design,
development & testing
WP4Battery module
eco-design, assembly &
testing
WP7Demonstration of battery module &
validation
WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line
WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)
WP8 Dissemination, Exploitation & Training
4.1- Battery module design
CIDETEC, CEGASA, AIT, RESCOLL, SEAT, VW
4.2 - Assembly processes development
CEGASA , CIDETEC, AIT, MASS
4.3 - Testing procedure
AIT, ENEA, CIDETEC, SEAT
4.4 - Battery module testing
AIT, ENEA
Design of the GREENLION battery modules
UNDER DISCUSSION
COUPLED WITH CELL DESIGN & ECODESIGN
MAIN ACHIEVEMENTS
SO FAR
WP2 Advancedelectrode
development & testing
WP3Cell design,
development & testing
WP4Battery module
eco-design, assembly &
testing
WP7Demonstration of battery module &
validation
WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line
WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)
WP8 Dissemination, Exploitation & Training
WP5 Manufacturing of electrodes, cells & modules in pilot-line
5.1: Electrode manufacturing process on pilot line
PCF, CEGASA, SOLVAY, TIMCAL, WWU5.2: Cell manufacturing process on pilot line
KEMET, CEGASA
5.3: Design battery module assembling processes/equipments
MASS, CEGASA
Electrode manufacturing :
transference from lab-coater
to industrial pilot line :
ALREADY STARTED
MAIN ACHIEVEMENTS
SO FAR
WP2 Advancedelectrode
development & testing
WP3Cell design,
development & testing
WP4Battery module
eco-design, assembly &
testing
WP7Demonstration of battery module &
validation
WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line
WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)
WP8 Dissemination, Exploitation & Training
WP6 Eco-design (LCA & Reuse/Recycling Strategies)
6.1: Regulatory assessment concerning REACH- CLP (GHS).
RESCOLL, TR, TIMCAL
Task 6.2: Eco-designTask 6.3: LCA
RESCOLL, TR, CEGASA, SEAT Task 6.4: Recycling/Reuse
TR, RESCOLL, CEGASA, WWU, TIMCAL
Benchmarking on recycling
processes done
LCA& ecodesign ;
gathering of inputs from partners
• reference cell
• Greenlion cell
MAIN ACHIEVEMENTS
SO FAR
WP2 Advancedelectrode
development & testing
WP3Cell design,
development & testing
WP4Battery module
eco-design, assembly &
testing
WP7Demonstration of battery module &
validation
WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line
WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)
WP8 Dissemination, Exploitation & Training
WP7Demonstration
of battery module
& validation
Task 7.1: Specs. of demonstrator and validation test plan
SEAT, CEGASA, VW
Task 7.2: Battery-pack production process validation
CEGASA , KEMET, MASS
Task 7.3: Testing and Validation of battery module
SEAT, VW
SCHEDULED FOR 4TH YEAR
WP7 parners already
contributing in other related
WPs, esp. in 4.1 Battery
module design
MAIN ACHIEVEMENTS
SO FAR
WP2 Advancedelectrode
development & testing
WP3Cell design,
development & testing
WP4Battery module
eco-design, assembly &
testing
WP7Demonstration of battery module &
validation
WP1 Management
WP5 Manufacturing of electrodes, cells & modules in pilot-line
WP6 Eco-design (Life Cycle Assessment & Reuse/Recycling Strategies)
WP8 Dissemination, Exploitation & Training
WP8 Dissemination, Exploitation& Training
8.1: Training activities
RESCOLL, All partners 8.2: Dissemination
RESCOLL, All partners
8.3: Exploitation of results
CEGASA, All partners
www.greenlionproject.eu
MAIN ACHIEVEMENTS
SO FAR
Exploitation Potential
•The key objective of GREENLION is to improve lithium ion battery cells & modules at
•cell and module components processing, assembly and manufacturing
•lowering production costs
•energy and environmentally friendly processes
...specifically aiming at electric vehicle applications.
•Ten out of sixteen partners (62%) in GREENLION are industries including:
• materials suppliers (SOLVAY, TIMCAL),
•machinery developers (POLYTYPE , KEMET, MONDRAGON ASSEMBLY),
•battery manufacturer (CEGASA),
•(recycling) process developer (TECNICAS REUNIDAS)
•automotive end-users (SEAT, VW).
...covering the whole battery manufacturing value chain
•Also, GREENLION will provide advances to a number of scientific and engineering challenges
for battery cell and module manufacturing.
•The successful resolution of these challenges will lead to breakthroughs in Li Ion batteries to
be directly exploitable by industry and scientific contributions to benefit the tech. community
Topics for cooperation within the cluster
• in contact with ELIBAMA similar project running in parallel:
• Participation in ELCAR project workshop on LCA:
ANYWAY:
• Several clusters of projects with related scope i.e. see program!!
• Cross-participation of individual partners in complementary projects i.e. GREENLION partners in:
HELIOS, AMELIE, CORE, SOMABAT, DELIVER, E3CAR, EDASH, ELVA, MOTORBRAIN, SMART-LIC.....
• Technical topics– materials, processing
– recycling, LCA
– BMS, module development
• Cross-cutting issues– benchmarking
– standards
• Dissemination & Training